Ford - Explorer Sport Trac 2wd - Workshop Manual - 2002 - 2002

Factory Workshop Manual Make Ford Model Explorer Sport Trac 2wd Engine and year V6-4.0L VIN E (2002) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0000-P00ZZ > P0065 - P0069, ( P0066 P0067 P0068 0065 0066 0067 0068 0069 ) > System Information > System Diagnosis P0065 - P0069: Testing and Inspection Ford directs the user to follow P1121 For diagnosis of code P0068, refer to P1121 in the following chart P071x Thru P1125 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0100 - P0104, ( P0101 P0102 P0103 0100 0101 0102 0103 0104 ) > System Information > System Diagnosis > P0102 P0100 - P0104: Testing and Inspection P0102 For diagnosis of code P0102 refer to chart Bxxxx, Cxxxx, P0068 Thru P0132 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0100 - P0104, ( P0101 P0102 P0103 0100 0101 0102 0103 0104 ) > System Information > System Diagnosis > P0102 > Page 13 P0100 - P0104: Testing and Inspection P0103 For diagnosis of code P0103 refer to chart Bxxxx, Cxxxx, P0068 Thru P0132 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109, ( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 P0105 - P0109: Testing and Inspection P0106 For diagnosis of code P0106 refer to chart Bxxxx, Cxxxx, P0068 Thru P0132 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109, ( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 18 P0105 - P0109: Testing and Inspection P0107 For diagnosis of code P0107 refer to chart Bxxxx, Cxxxx, P0068 Thru P0132 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109, ( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 19 P0105 - P0109: Testing and Inspection P0108 For diagnosis of code P0108 refer to chart Bxxxx, Cxxxx, P0068 Thru P0132 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109, ( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 20 P0105 - P0109: Testing and Inspection P0109 For diagnosis of code P0109 refer to chart Bxxxx, Cxxxx, P0068 Thru P0132 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0110 - P0114, ( P0111 P0112 P0113 0110 0111 0112 0113 0114 ) > System Information > System Diagnosis > P0112 P0110 - P0114: Testing and Inspection P0112 For diagnosis of code P0112 refer to chart Bxxxx, Cxxxx, P0068 Thru P0132 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0110 - P0114, ( P0111 P0112 P0113 0110 0111 0112 0113 0114 ) > System Information > System Diagnosis > P0112 > Page 25 P0110 - P0114: Testing and Inspection P0113 For diagnosis of code P0113 refer to chart Bxxxx, Cxxxx, P0068 Thru P0132 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0115 - P0119, ( P0116 P0117 P0118 0115 0116 0117 0118 0119 ) > System Information > System Diagnosis > P0116 P0115 - P0119: Testing and Inspection P0116 For diagnosis of code P0116 refer to chart Bxxxx, Cxxxx, P0068 Thru P0132 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0115 - P0119, ( P0116 P0117 P0118 0115 0116 0117 0118 0119 ) > System Information > System Diagnosis > P0116 > Page 30 P0115 - P0119: Testing and Inspection P0117 For diagnosis of code P0117 refer to chart Bxxxx, Cxxxx, P0068 Thru P0132 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0115 - P0119, ( P0116 P0117 P0118 0115 0116 0117 0118 0119 ) > System Information > System Diagnosis > P0116 > Page 31 P0115 - P0119: Testing and Inspection P0118 For diagnosis of code P0118 refer to chart Bxxxx, Cxxxx, P0068 Thru P0132 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0120 - P0124, ( P0121 P0122 P0123 0120 0121 0122 0123 0124 ) > System Information > System Diagnosis > P0121 P0120 - P0124: Testing and Inspection P0121 For diagnosis of code P0121 refer to chart Bxxxx, Cxxxx, P0068 Thru P0132 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0120 - P0124, ( P0121 P0122 P0123 0120 0121 0122 0123 0124 ) > System Information > System Diagnosis > P0121 > Page 36 P0120 - P0124: Testing and Inspection P0122 For diagnosis of code P0122 refer to chart Bxxxx, Cxxxx, P0068 Thru P0132 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0120 - P0124, ( P0121 P0122 P0123 0120 0121 0122 0123 0124 ) > System Information > System Diagnosis > P0121 > Page 37 P0120 - P0124: Testing and Inspection P0123 For diagnosis of code P0123 refer to chart Bxxxx, Cxxxx, P0068 Thru P0132 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0125 - P0129, ( P0126 P0127 P0128 0125 0126 0127 0128 0129 ) > System Information > System Diagnosis > P0125 P0125 - P0129: Testing and Inspection P0125 For diagnosis of code P0125 refer to chart Bxxxx, Cxxxx, P0068 Thru P0132 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0125 - P0129, ( P0126 P0127 P0128 0125 0126 0127 0128 0129 ) > System Information > System Diagnosis > P0125 > Page 42 P0125 - P0129: Testing and Inspection P0128 For diagnosis of code P0128 refer to chart Bxxxx, Cxxxx, P0068 Thru P0132 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0130 - P0134, ( P0131 P0132 P0133 0130 0131 0132 0133 0134 ) > System Information > System Diagnosis > P0131 P0130 - P0134: Testing and Inspection P0131 For diagnosis of code P0131 refer to chart Bxxxx, Cxxxx, P0068 Thru P0132 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0130 - P0134, ( P0131 P0132 P0133 0130 0131 0132 0133 0134 ) > System Information > System Diagnosis > P0131 > Page 47 P0130 - P0134: Testing and Inspection P0132 For diagnosis of code P0132 refer to chart Bxxxx, Cxxxx, P0068 Thru P0132 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0130 - P0134, ( P0131 P0132 P0133 0130 0131 0132 0133 0134 ) > System Information > System Diagnosis > P0131 > Page 48 P0130 - P0134: Testing and Inspection P0133 For diagnosis of code P0133 refer to chart P0133 Thru P0190 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0135 - P0139, ( P0136 P0137 P0138 0135 0136 0137 0138 0139 ) > System Information > System Diagnosis > P0135 P0135 - P0139: Testing and Inspection P0135 For diagnosis of code P0135 refer to chart P0133 Thru P0190 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0135 - P0139, ( P0136 P0137 P0138 0135 0136 0137 0138 0139 ) > System Information > System Diagnosis > P0135 > Page 53 P0135 - P0139: Testing and Inspection P0136 For diagnosis of code P0136 refer to chart P0133 Thru P0190 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0135 - P0139, ( P0136 P0137 P0138 0135 0136 0137 0138 0139 ) > System Information > System Diagnosis > P0135 > Page 54 P0135 - P0139: Testing and Inspection P0138 For diagnosis of code P0138 refer to chart P0133 Thru P0190 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0140 - P0144, ( P0141 P0142 P0143 0140 0141 0142 0143 0144 ) > System Information > System Diagnosis P0140 - P0144: Testing and Inspection For diagnosis of code P0141 refer to chart P0133 Thru P0190 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0145 - P0149, ( P0146 P0127 P0148 0145 0146 0147 0148 0149 ) > System Information > System Diagnosis P0145 - P0149: Testing and Inspection For diagnosis of code P0148 refer to chart P0133 Thru P0190 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0150 - P0154, ( P0151 P0152 P0153 0150 0151 0152 0153 0154 ) > System Information > System Diagnosis > P0151 P0150 - P0154: Testing and Inspection P0151 For diagnosis of code P0151 refer to chart P0133 Thru P0190 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0150 - P0154, ( P0151 P0152 P0153 0150 0151 0152 0153 0154 ) > System Information > System Diagnosis > P0151 > Page 65 P0150 - P0154: Testing and Inspection P0152 For diagnosis of code P0152 refer to chart P0133 Thru P0190 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0150 - P0154, ( P0151 P0152 P0153 0150 0151 0152 0153 0154 ) > System Information > System Diagnosis > P0151 > Page 66 P0150 - P0154: Testing and Inspection P0153 For diagnosis of code P0153 refer to chart P0133 Thru P0190 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0155 - P0159, ( P0156 P0157 P0158 0155 0156 0157 0158 0159 ) > System Information > System Diagnosis > P0155 P0155 - P0159: Testing and Inspection P0155 For diagnosis of code P0155 refer to chart P0133 Thru P0190 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0155 - P0159, ( P0156 P0157 P0158 0155 0156 0157 0158 0159 ) > System Information > System Diagnosis > P0155 > Page 71 P0155 - P0159: Testing and Inspection P0156 For diagnosis of code P0156 refer to chart P0133 Thru P0190 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0155 - P0159, ( P0156 P0157 P0158 0155 0156 0157 0158 0159 ) > System Information > System Diagnosis > P0155 > Page 72 P0155 - P0159: Testing and Inspection P0158 For diagnosis of code P0158 refer to chart P0133 Thru P0190 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0160 - P0164, ( P0161 P0162 P0163 0160 0161 0162 0163 0164 ) > System Information > System Diagnosis P0160 - P0164: Testing and Inspection For diagnosis of code P0161 refer to chart P0133 Thru P0190 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0170 - P0174, ( P0171 P0172 P0173 0170 0171 0172 0173 0174 ) > System Information > System Diagnosis > P0171 P0170 - P0174: Testing and Inspection P0171 For diagnosis of code P0171 refer to chart P0133 Thru P0190 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0170 - P0174, ( P0171 P0172 P0173 0170 0171 0172 0173 0174 ) > System Information > System Diagnosis > P0171 > Page 80 P0170 - P0174: Testing and Inspection P0172 For diagnosis of code P0172 refer to chart P0133 Thru P0190 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0170 - P0174, ( P0171 P0172 P0173 0170 0171 0172 0173 0174 ) > System Information > System Diagnosis > P0171 > Page 81 P0170 - P0174: Testing and Inspection P0174 For diagnosis of code P0174 refer to chart P0133 Thru P0190 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0175 - P0179, ( P0176 P0177 P0178 0175 0176 0177 0178 0179 ) > System Information > System Diagnosis P0175 - P0179: Testing and Inspection For diagnosis of code P0175 refer to chart P0133 Thru P0190 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184, ( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 P0180 - P0184: Testing and Inspection P0180 For diagnosis of code P0180 refer to chart P0133 Thru P0190 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184, ( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 89 P0180 - P0184: Testing and Inspection P0181 For diagnosis of code P0181 refer to chart P0133 Thru P0190 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184, ( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 90 P0180 - P0184: Testing and Inspection P0183 For diagnosis of code P0183 refer to chart P0133 Thru P0190 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194, ( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 P0190 - P0194: Testing and Inspection P0190 For diagnosis of code P0190 refer to chart P0133 Thru P0190 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194, ( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 95 P0190 - P0194: Testing and Inspection P0191 For diagnosis of code P0191 refer to chart P0191 Thru P0303 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194, ( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 96 P0190 - P0194: Testing and Inspection P0192 For diagnosis of code P0192 refer to chart P0191 Thru P0303 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194, ( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 97 P0190 - P0194: Testing and Inspection P0193 For diagnosis of code P0193 refer to chart P0191 Thru P0303 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204, ( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 P0200 - P0204: Testing and Inspection P0201 For diagnosis of code P0201 refer to chart P0191 Thru P0303 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204, ( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 > Page 103 P0200 - P0204: Testing and Inspection P0202 For diagnosis of code P0202 refer to chart P0191 Thru P0303 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204, ( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 > Page 104 P0200 - P0204: Testing and Inspection P0203 For diagnosis of code P0203 refer to chart P0191 Thru P0303 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204, ( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 > Page 105 P0200 - P0204: Testing and Inspection P0204 For diagnosis of code P0204 refer to chart P0191 Thru P0303 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 P0205 - P0209: Testing and Inspection P0205 For diagnosis of code P0205 refer to chart P0191 Thru P0303 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 110 P0205 - P0209: Testing and Inspection P0206 For diagnosis of code P0206 refer to chart P0191 Thru P0303 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 111 P0205 - P0209: Testing and Inspection P0207 For diagnosis of code P0207 refer to chart P0191 Thru P0303 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 112 P0205 - P0209: Testing and Inspection P0208 For diagnosis of code P0208 refer to chart P0191 Thru P0303 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 113 P0205 - P0209: Testing and Inspection P0209 For diagnosis of code P0209 refer to chart P0191 Thru P0303 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0210 - P0214, ( P0211 P0212 P0213 0210 0211 0212 0213 0214 ) > System Information > System Diagnosis > P0210 P0210 - P0214: Testing and Inspection P0210 For diagnosis of code P0210 refer to chart P0191 Thru P0303 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0210 - P0214, ( P0211 P0212 P0213 0210 0211 0212 0213 0214 ) > System Information > System Diagnosis > P0210 > Page 118 P0210 - P0214: Testing and Inspection P0211 For diagnosis of code P0211 refer to chart P0191 Thru P0303 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0210 - P0214, ( P0211 P0212 P0213 0210 0211 0212 0213 0214 ) > System Information > System Diagnosis > P0210 > Page 119 P0210 - P0214: Testing and Inspection P0212 For diagnosis of code P0212 refer to chart P0191 Thru P0303 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234, ( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 P0230 - P0234: Testing and Inspection P0230 For diagnosis of code P0230 refer to chart P0191 Thru P0303 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234, ( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 > Page 124 P0230 - P0234: Testing and Inspection P0231 For diagnosis of code P0231 refer to chart P0191 Thru P0303 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234, ( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 > Page 125 P0230 - P0234: Testing and Inspection P0232 For diagnosis of code P0232 refer to chart P0191 Thru P0303 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 P0300 - P0304: Testing and Inspection P0300 For diagnosis of code P0300 refer to chart P0191 Thru P0303 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 131 P0300 - P0304: Testing and Inspection P0301 For diagnosis of code P0301 refer to chart P0191 Thru P0303 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 132 P0300 - P0304: Testing and Inspection P0302 For diagnosis of code P0302 refer to chart P0191 Thru P0303 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 133 P0300 - P0304: Testing and Inspection P0303 For diagnosis of code P0303 refer to chart P0191 Thru P0303 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 134 P0300 - P0304: Testing and Inspection P0304 For diagnosis of code P0304 refer to chart P0304 Thru P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 P0305 - P0309: Testing and Inspection P0305 For diagnosis of code P0305 refer to chart P0304 Thru P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 139 P0305 - P0309: Testing and Inspection P0306 For diagnosis of code P0306 refer to chart P0304 Thru P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 140 P0305 - P0309: Testing and Inspection P0307 For diagnosis of code P0307 refer to chart P0304 Thru P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 141 P0305 - P0309: Testing and Inspection P0308 For diagnosis of code P0308 refer to chart P0304 Thru P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0310 - P0314, ( P0311 P0312 P0313 0310 0311 0312 0313 0314 ) > System Information > System Diagnosis P0310 - P0314: Testing and Inspection For diagnosis of code P0310 refer to chart P0304 Thru P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0315 - P0319, ( P0316 P0317 P0318 0315 0316 0317 0318 0319 ) > System Information > System Diagnosis > P0315 P0315 - P0319: Testing and Inspection P0315 For diagnosis of code P0315 refer to chart P0304 Thru P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0315 - P0319, ( P0316 P0317 P0318 0315 0316 0317 0318 0319 ) > System Information > System Diagnosis > P0315 > Page 149 P0315 - P0319: Testing and Inspection P0316 For diagnosis of code P0316 refer to chart P0304 Thru P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0320 - P0324, ( P0321 P0322 P0323 0320 0321 0322 0323 0324 ) > System Information > System Diagnosis P0320 - P0324: Testing and Inspection For diagnosis of code P0320 refer to chart P0304 Thru P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0325 - P0329, ( P0326 P0327 P0328 0325 0326 0327 0328 0329 ) > System Information > System Diagnosis > P0325 P0325 - P0329: Testing and Inspection P0325 For diagnosis of code P0325 refer to chart P0304 Thru P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0325 - P0329, ( P0326 P0327 P0328 0325 0326 0327 0328 0329 ) > System Information > System Diagnosis > P0325 > Page 157 P0325 - P0329: Testing and Inspection P0326 For diagnosis of code P0326 refer to chart P0304 Thru P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0330 - P0334, ( P0331 P0332 P0333 0330 0331 0332 0333 0334 ) > System Information > System Diagnosis > P0330 P0330 - P0334: Testing and Inspection P0330 For diagnosis of code P0330 refer to chart P0304 Thru P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0330 - P0334, ( P0331 P0332 P0333 0330 0331 0332 0333 0334 ) > System Information > System Diagnosis > P0330 > Page 162 P0330 - P0334: Testing and Inspection P0331 For diagnosis of code P0331 refer to chart P0304 Thru P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0340 - P0344, ( P0341 P0342 P0343 0340 0341 0342 0343 0344 ) > System Information > System Diagnosis P0340 - P0344: Testing and Inspection For diagnosis of code P0340 refer to chart P0304 Thru P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 P0350 - P0354: Testing and Inspection P0350 For diagnosis of code P0350 refer to chart P0304 Thru P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 170 P0350 - P0354: Testing and Inspection P0351 For diagnosis of code P0351 refer to chart P0304 Thru P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 171 P0350 - P0354: Testing and Inspection P0352 For diagnosis of code P0352 refer to chart P0304 Thru P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 172 P0350 - P0354: Testing and Inspection P0353 For diagnosis of code P0353 refer to chart P0304 Thru P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 173 P0350 - P0354: Testing and Inspection P0354 For diagnosis of code P0354 refer to chart P0304 Thru P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 P0355 - P0359: Testing and Inspection P0355 For diagnosis of code P0355 refer to chart P0304 Thru P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 178 P0355 - P0359: Testing and Inspection P0356 For diagnosis of code P0356 refer to chart P0304 Thru P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 179 P0355 - P0359: Testing and Inspection P0357 For diagnosis of code P0357 refer to chart P0304 Thru P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 180 P0355 - P0359: Testing and Inspection P0358 For diagnosis of code P0358 refer to chart P0304 Thru P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 181 P0355 - P0359: Testing and Inspection P0359 For diagnosis of code P0359 refer to chart P0304 Thru P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0360 - P0364, ( P0361 P0362 P0363 0360 0361 0362 0363 0364 ) > System Information > System Diagnosis P0360 - P0364: Testing and Inspection For diagnosis of code P0360 refer to chart P0304 Thru P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404, ( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0401 P0400 - P0404: Testing and Inspection P0401 For diagnosis of code P0401 refer to chart P0400 Thru P0500 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404, ( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0401 > Page 190 P0400 - P0404: Testing and Inspection P0402 For diagnosis of code P0402 refer to chart P0400 Thru P0500 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0405 - P0409, ( P0406 P0407 P0408 0405 0406 0407 0408 0409 ) > System Information > System Diagnosis > P0405 P0405 - P0409: Testing and Inspection P0405 For diagnosis of code P0405 refer to chart P0400 Thru P0500 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0405 - P0409, ( P0406 P0407 P0408 0405 0406 0407 0408 0409 ) > System Information > System Diagnosis > P0405 > Page 195 P0405 - P0409: Testing and Inspection P0406 For diagnosis of code P0406 refer to chart P0400 Thru P0500 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0410 - P0414, ( P0411 P0412 P0413 0410 0411 0412 0413 0414 ) > System Information > System Diagnosis > P0411 P0410 - P0414: Testing and Inspection P0411 For diagnosis of code P0411 refer to chart P0400 Thru P0500 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0410 - P0414, ( P0411 P0412 P0413 0410 0411 0412 0413 0414 ) > System Information > System Diagnosis > P0411 > Page 200 P0410 - P0414: Testing and Inspection P0412 For diagnosis of code P0412 refer to chart P0400 Thru P0500 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0420 - P0424, ( P0421 P0422 P0423 0420 0421 0422 0423 0424 ) > System Information > System Diagnosis P0420 - P0424: Testing and Inspection For diagnosis of code P0420 refer to chart P0400 Thru P0500 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0430 - P0434, ( P0431 P0432 P0433 0430 0431 0432 0433 0434 ) > System Information > System Diagnosis P0430 - P0434: Testing and Inspection For diagnosis of code P0430 refer to chart P0400 Thru P0500 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0440 - P0444, ( P0441 P0442 P0443 0440 0441 0442 0443 0444 ) > System Information > System Diagnosis > P0442 P0440 - P0444: Testing and Inspection P0442 For diagnosis of code P0442 refer to chart DTC Index P0442 - P0457 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Evaporative Emissions diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0440 - P0444, ( P0441 P0442 P0443 0440 0441 0442 0443 0444 ) > System Information > System Diagnosis > P0442 > Page 211 P0440 - P0444: Testing and Inspection P0443 For diagnosis of code P0443 refer to chart P0400 Thru P0500 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0445 - P0449, ( P0446 P0447 P0448 0445 0446 0447 0448 0449 ) > System Information > System Diagnosis P0445 - P0449: Testing and Inspection Ford directs the user to follow P1451 For diagnosis of code P0446, refer to P1451 in the following chart P1405 Thru P1501 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0450 - P0454, ( P0451 P0452 P0453 0450 0451 0452 0453 0454 ) > System Information > System Diagnosis > P0451 P0450 - P0454: Testing and Inspection P0451 For diagnosis of code P0451 refer to chart P0400 Thru P0500 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0450 - P0454, ( P0451 P0452 P0453 0450 0451 0452 0453 0454 ) > System Information > System Diagnosis > P0451 > Page 219 P0450 - P0454: Testing and Inspection P0452 For diagnosis of code P0452 refer to chart P0400 Thru P0500 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0450 - P0454, ( P0451 P0452 P0453 0450 0451 0452 0453 0454 ) > System Information > System Diagnosis > P0451 > Page 220 P0450 - P0454: Testing and Inspection P0453 For diagnosis of code P0453 refer to chart P0400 Thru P0500 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0455 - P0459, ( P0456 P0457 P0458 0455 0456 0457 0458 0459 ) > System Information > System Diagnosis > P0455 P0455 - P0459: Testing and Inspection P0455 For diagnosis of code P0455 refer to chart DTC Index P0442 - P0457 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Evaporative Emissions diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0455 - P0459, ( P0456 P0457 P0458 0455 0456 0457 0458 0459 ) > System Information > System Diagnosis > P0455 > Page 225 P0455 - P0459: Testing and Inspection P0456 For diagnosis of code P0456 refer to chart DTC Index P0442 - P0457 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Evaporative Emissions diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0455 - P0459, ( P0456 P0457 P0458 0455 0456 0457 0458 0459 ) > System Information > System Diagnosis > P0455 > Page 226 P0455 - P0459: Testing and Inspection P0457 For diagnosis of P0457 refer to the system experiencing the problem. Computers and Control Systems P0400 Thru P0500 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Evaporative Emissions System Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0455 - P0459, ( P0456 P0457 P0458 0455 0456 0457 0458 0459 ) > System Information > System Diagnosis > P0455 > Page 227 DTC Index P0442 - P0457 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Evaporative Emissions diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0460 - P0464, ( P0461 P0462 P0463 0460 0461 0462 0463 0464 ) > System Information > System Diagnosis > P0460 P0460 - P0464: Testing and Inspection P0460 For diagnosis of code P0460 refer to chart P0400 Thru P0500 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0460 - P0464, ( P0461 P0462 P0463 0460 0461 0462 0463 0464 ) > System Information > System Diagnosis > P0460 > Page 232 P0460 - P0464: Testing and Inspection P0461 For diagnosis of code P0461 refer to chart P0400 Thru P0500 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0480 - P0484, ( P0481 P0482 P0483 0480 0481 0482 0483 0484 ) > System Information > System Diagnosis P0480 - P0484: Testing and Inspection For diagnosis of code P0480 refer to chart P0400 Thru P0500 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 P0500 - P0504: Testing and Inspection P0500 For diagnosis of P0500 refer to the system experiencing the problem. Computers and Control Systems or Transmission Control System P0400 Thru P0500 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Transfer Case Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 241 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case, follow this link: Windshield Wiper Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 242 DTC Index P0500 - B1434 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Windshield Wiper diagnostic information, See: Wiper and Washer Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 243 P0500 - P0504: Testing and Inspection P0501 For diagnosis of code P0501 refer to chart P0501 Thru P0708 NOTE 12: Vehicle speed information is provided by the Anti-lock Brake System (ABS). If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete ABS diagnosis, See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 244 P0500 - P0504: Testing and Inspection P0503 For diagnosis of code P0503 refer to chart P0501 Thru P0708 NOTE 12: Vehicle speed information is provided by the Anti-lock Brake System (ABS). If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete ABS diagnosis, See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0505 - P0509, ( P0506 P0507 P0508 0505 0506 0507 0508 0509 ) > System Information > System Diagnosis > P0505 P0505 - P0509: Testing and Inspection P0505 For diagnosis of code P0505 refer to chart P0501 Thru P0708 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0505 - P0509, ( P0506 P0507 P0508 0505 0506 0507 0508 0509 ) > System Information > System Diagnosis > P0505 > Page 249 P0505 - P0509: Testing and Inspection P0506 Ford directs the user to follow P1507 For diagnosis of code P0506, refer to P1507 in the following chart P1502 Thru P1640 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0505 - P0509, ( P0506 P0507 P0508 0505 0506 0507 0508 0509 ) > System Information > System Diagnosis > P0505 > Page 250 P0505 - P0509: Testing and Inspection P0507 Ford directs the user to follow P1506 For diagnosis of code P0507, refer to P1506 in the following chart P1502 Thru P1640 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0510 - P0514, ( P0511 P0512 P0513 0510 0511 0512 0513 0514 ) > System Information > System Diagnosis P0510 - P0514: Testing and Inspection Ford directs the user to follow P1504 For diagnosis of code P0511, refer to P1504 in the following chart P1502 Thru P1640 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0525 - P0529, ( P0526 P0527 P0528 0525 0526 0527 0528 0529 ) > System Information > System Diagnosis P0525 - P0529: Testing and Inspection For diagnosis of code P0528 refer to chart P0501 Thru P0708 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0550 - P0554, ( P0551 P0552 P0553 0550 0551 0552 0553 0554 ) > System Information > System Diagnosis > P0552 P0550 - P0554: Testing and Inspection P0552 For diagnosis of code P0552 refer to chart P0501 Thru P0708 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0550 - P0554, ( P0551 P0552 P0553 0550 0551 0552 0553 0554 ) > System Information > System Diagnosis > P0552 > Page 261 P0550 - P0554: Testing and Inspection P0553 For diagnosis of code P0553 refer to chart P0501 Thru P0708 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0600 - P0604, ( P0601 P0602 P0603 0600 0601 0602 0603 0604 ) > System Information > System Diagnosis > P0602 P0600 - P0604: Testing and Inspection P0602 For diagnosis of code P0602 refer to chart P0501 Thru P0708 NOTE 11: The Vehicle ID block (VID) needs to be reprogrammed. For instructions refer to the Flash VID Block Procedure, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0600 - P0604, ( P0601 P0602 P0603 0600 0601 0602 0603 0604 ) > System Information > System Diagnosis > P0602 > Page 267 P0600 - P0604: Testing and Inspection P0603 For diagnosis of code P0603 refer to chart P0501 Thru P0708 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0605 - P0609, ( P0606 P0607 P0608 0605 0606 0607 0608 0609 ) > System Information > System Diagnosis > P0605 P0605 - P0609: Testing and Inspection P0605 For diagnosis of code P0605 refer to chart P0501 Thru P0708 NOTE 14: Be sure to check for aftermarket performance products before replacing PCM (If replacement is necessary refer to Flash Electrically Erasable Programmable Read Only Memory (EEPROM). See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0605 - P0609, ( P0606 P0607 P0608 0605 0606 0607 0608 0609 ) > System Information > System Diagnosis > P0605 > Page 272 P0605 - P0609: Testing and Inspection P0606 For diagnosis of code P0606 refer to chart P0501 Thru P0708 NOTE 14: Be sure to check for aftermarket performance products before replacing PCM (If replacement is necessary refer to Flash Electrically Erasable Programmable Read Only Memory (EEPROM). See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0645 - P0649, ( P0646 P0647 P0648 0645 0646 0647 0648 0649 ) > System Information > System Diagnosis P0645 - P0649: Testing and Inspection Vechicles With A Constant Control Relay Module (CCRM): Ford directs the user to follow P1460 For diagnosis of code P0645, refer to P1460 in the following chart P1405 Thru P1501 All Other Vehicles: For diagnosis of code P0645 refer to chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0645 - P0649, ( P0646 P0647 P0648 0645 0646 0647 0648 0649 ) > System Information > System Diagnosis > Page 276 P0501 Thru P0708 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0700 - P0704, ( P0701 P0702 P0703 0700 0701 0702 0703 0704 ) > System Information > System Diagnosis > P0703 P0700 - P0704: Testing and Inspection P0703 For diagnosis of code P0703 refer to chart P0501 Thru P0708 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0700 - P0704, ( P0701 P0702 P0703 0700 0701 0702 0703 0704 ) > System Information > System Diagnosis > P0703 > Page 282 P0700 - P0704: Testing and Inspection P0704 For diagnosis of code P0704 refer to chart P0501 Thru P0708 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709, ( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705 P0705 - P0709: Testing and Inspection P0705 For diagnosis of code P0705 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709, ( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705 > Page 287 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709, ( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705 > Page 288 P0705 - P0709: Testing and Inspection P0708 For diagnosis of code P0708 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709, ( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705 > Page 289 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0710 - P0714, ( P0711 P0712 P0713 0710 0711 0712 0713 0714 ) > System Information > System Diagnosis > P0712 P0710 - P0714: Testing and Inspection P0712 For diagnosis of code P0712 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0710 - P0714, ( P0711 P0712 P0713 0710 0711 0712 0713 0714 ) > System Information > System Diagnosis > P0712 > Page 294 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0710 - P0714, ( P0711 P0712 P0713 0710 0711 0712 0713 0714 ) > System Information > System Diagnosis > P0712 > Page 295 P0710 - P0714: Testing and Inspection P0713 For diagnosis of code P0713 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0710 - P0714, ( P0711 P0712 P0713 0710 0711 0712 0713 0714 ) > System Information > System Diagnosis > P0712 > Page 296 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0715 - P0719, ( P0716 P0717 P0718 0715 0716 0717 0718 0719 ) > System Information > System Diagnosis P0715 - P0719: Testing and Inspection For diagnosis of code P0715 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0715 - P0719, ( P0716 P0717 P0718 0715 0716 0717 0718 0719 ) > System Information > System Diagnosis > Page 300 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > Manual Transmission P0720 - P0724: Testing and Inspection Manual Transmission For diagnosis of code P072x refer to chart P071x Thru P1125 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Note: "x" = any number 0 thru 9 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > Manual Transmission > Page 305 P0720 - P0724: Testing and Inspection Automatic Transmission P0720 For diagnosis of code P0720 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection P0721 For diagnosis of code P0721 refer to chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > Manual Transmission > Page 306 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734, ( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731 P0730 - P0734: Testing and Inspection P0731 For diagnosis of code P0731 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734, ( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731 > Page 311 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734, ( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731 > Page 312 P0730 - P0734: Testing and Inspection P0732 For diagnosis of code P0732 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734, ( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731 > Page 313 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734, ( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731 > Page 314 P0730 - P0734: Testing and Inspection P0733 For diagnosis of code P0733 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734, ( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731 > Page 315 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734, ( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731 > Page 316 P0730 - P0734: Testing and Inspection P0734 For diagnosis of code P0734 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0735 - P0739, ( P0736 P0737 P0738 0735 0736 0737 0738 0739 ) > System Information > System Diagnosis P0735 - P0739: Testing and Inspection For diagnosis of code P0735 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0735 - P0739, ( P0736 P0737 P0738 0735 0736 0737 0738 0739 ) > System Information > System Diagnosis > Page 320 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0740 - P0744, ( P0741 P0742 P0743 0740 0741 0742 0743 0744 ) > System Information > System Diagnosis > P0741 P0740 - P0744: Testing and Inspection P0741 For diagnosis of code P0741 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0740 - P0744, ( P0741 P0742 P0743 0740 0741 0742 0743 0744 ) > System Information > System Diagnosis > P0741 > Page 325 - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0740 - P0744, ( P0741 P0742 P0743 0740 0741 0742 0743 0744 ) > System Information > System Diagnosis > P0741 > Page 326 P0740 - P0744: Testing and Inspection P0743 For diagnosis of code P0743 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0740 - P0744, ( P0741 P0742 P0743 0740 0741 0742 0743 0744 ) > System Information > System Diagnosis > P0741 > Page 327 - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0750 - P0754, ( P0751 P0752 P0753 0750 0751 0752 0753 0754 ) > System Information > System Diagnosis > P0750 P0750 - P0754: Testing and Inspection P0750 For diagnosis of code P0750 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0750 - P0754, ( P0751 P0752 P0753 0750 0751 0752 0753 0754 ) > System Information > System Diagnosis > P0750 > Page 332 P0750 - P0754: Testing and Inspection P0753 For diagnosis of code P0753 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0755 - P0759, ( P0756 P0757 P0758 0755 0756 0757 0758 0759 ) > System Information > System Diagnosis > P0755 P0755 - P0759: Testing and Inspection P0755 For diagnosis of code P0755 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0755 - P0759, ( P0756 P0757 P0758 0755 0756 0757 0758 0759 ) > System Information > System Diagnosis > P0755 > Page 337 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0755 - P0759, ( P0756 P0757 P0758 0755 0756 0757 0758 0759 ) > System Information > System Diagnosis > P0755 > Page 338 P0755 - P0759: Testing and Inspection P0758 For diagnosis of code P0758 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0755 - P0759, ( P0756 P0757 P0758 0755 0756 0757 0758 0759 ) > System Information > System Diagnosis > P0755 > Page 339 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0760 - P0764, ( P0761 P0762 P0763 0760 0761 0762 0763 0764 ) > System Information > System Diagnosis > P0760 P0760 - P0764: Testing and Inspection P0760 For diagnosis of code P0760 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0760 - P0764, ( P0761 P0762 P0763 0760 0761 0762 0763 0764 ) > System Information > System Diagnosis > P0760 > Page 344 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0760 - P0764, ( P0761 P0762 P0763 0760 0761 0762 0763 0764 ) > System Information > System Diagnosis > P0760 > Page 345 P0760 - P0764: Testing and Inspection P0763 For diagnosis of code P0763 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0760 - P0764, ( P0761 P0762 P0763 0760 0761 0762 0763 0764 ) > System Information > System Diagnosis > P0760 > Page 346 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0765 - P0769, ( P0766 P0767 P0768 0765 0766 0767 0768 0769 ) > System Information > System Diagnosis > P0765 P0765 - P0769: Testing and Inspection P0765 For diagnosis of code P0765 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0765 - P0769, ( P0766 P0767 P0768 0765 0766 0767 0768 0769 ) > System Information > System Diagnosis > P0765 > Page 351 P0765 - P0769: Testing and Inspection P0768 For diagnosis of code P0768 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0790 - P0794, ( P0791 P0792 P0793 0790 0791 0792 0793 0794 ) > System Information > System Diagnosis > P0791 P0790 - P0794: Testing and Inspection P0791 For diagnosis of code P0791 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0790 - P0794, ( P0791 P0792 P0793 0790 0791 0792 0793 0794 ) > System Information > System Diagnosis > P0791 > Page 356 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0790 - P0794, ( P0791 P0792 P0793 0790 0791 0792 0793 0794 ) > System Information > System Diagnosis > P0791 > Page 357 P0790 - P0794: Testing and Inspection P0794 For diagnosis of code P0794 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0790 - P0794, ( P0791 P0792 P0793 0790 0791 0792 0793 0794 ) > System Information > System Diagnosis > P0791 > Page 358 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection94 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0800-P08ZZ > P0810 - P0814, ( P0811 P0812 P0813 0810 0811 0812 0813 0814 ) > System Information > System Diagnosis P0810 - P0814: Testing and Inspection For diagnosis of code P0812 refer to chart P071x Thru P1125 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1000-P10ZZ > P1000 - P1004, ( P1001 P1002 P1003 1000 1001 1002 1003 1004 ) > System Information > System Diagnosis > P1000 P1000 - P1004: Testing and Inspection P1000 For diagnosis of code P1000 refer to chart P071x Thru P1125 NOTE 1: DTC P1000 is ignored in KOEO and KOER Self-Test. Disregard the DTC P1000 and continure as directed. If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1000-P10ZZ > P1000 - P1004, ( P1001 P1002 P1003 1000 1001 1002 1003 1004 ) > System Information > System Diagnosis > P1000 > Page 368 P1000 - P1004: Testing and Inspection P1001 For diagnosis of code P1001 refer to chart P071x Thru P1125 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1100 - P1104, ( P1101 P1102 P1103 1100 1101 1102 1103 1104 ) > System Information > System Diagnosis > P1100 P1100 - P1104: Testing and Inspection P1100 For diagnosis of code P1100 refer to chart P071x Thru P1125 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1100 - P1104, ( P1101 P1102 P1103 1100 1101 1102 1103 1104 ) > System Information > System Diagnosis > P1100 > Page 374 P1100 - P1104: Testing and Inspection P1101 For diagnosis of code P1101 refer to chart P071x Thru P1125 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1110 - P1114, ( P1111 P1112 P1113 1110 1111 1112 1113 1114 ) > System Information > System Diagnosis > P1112 P1110 - P1114: Testing and Inspection P1112 For diagnosis of code P1112 refer to chart P071x Thru P1125 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1110 - P1114, ( P1111 P1112 P1113 1110 1111 1112 1113 1114 ) > System Information > System Diagnosis > P1112 > Page 379 P1110 - P1114: Testing and Inspection P1114 For diagnosis of code P1114 refer to chart P071x Thru P1125 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1115 - P1119, ( P1116 P1117 P1118 1115 1116 1117 1118 1119 ) > System Information > System Diagnosis > P1115 P1115 - P1119: Testing and Inspection P1115 For diagnosis of code P1115 refer to chart P071x Thru P1125 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1115 - P1119, ( P1116 P1117 P1118 1115 1116 1117 1118 1119 ) > System Information > System Diagnosis > P1115 > Page 384 P1115 - P1119: Testing and Inspection P1116 For diagnosis of code P1116 refer to chart P071x Thru P1125 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1115 - P1119, ( P1116 P1117 P1118 1115 1116 1117 1118 1119 ) > System Information > System Diagnosis > P1115 > Page 385 P1115 - P1119: Testing and Inspection P1117 For diagnosis of code P1117 refer to chart P071x Thru P1125 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1120 - P1124, ( P1121 P1122 P1123 1120 1121 1122 1123 1124 ) > System Information > System Diagnosis > P1120 P1120 - P1124: Testing and Inspection P1120 For diagnosis of code P1120 refer to chart P071x Thru P1125 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1120 - P1124, ( P1121 P1122 P1123 1120 1121 1122 1123 1124 ) > System Information > System Diagnosis > P1120 > Page 390 P1120 - P1124: Testing and Inspection P1121 For diagnosis of code P1121 refer to chart P071x Thru P1125 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1120 - P1124, ( P1121 P1122 P1123 1120 1121 1122 1123 1124 ) > System Information > System Diagnosis > P1120 > Page 391 P1120 - P1124: Testing and Inspection P1124 For diagnosis of code P1124 refer to chart P071x Thru P1125 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129, ( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 P1125 - P1129: Testing and Inspection P1125 For diagnosis of code P1125 refer to chart P071x Thru P1125 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129, ( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 396 P1125 - P1129: Testing and Inspection P1127 For diagnosis of code P1127 refer to chart P1127 Thru P1232 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129, ( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 397 P1125 - P1129: Testing and Inspection P1128 For diagnosis of code P1128 refer to chart P1127 Thru P1232 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129, ( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 398 P1125 - P1129: Testing and Inspection P1129 For diagnosis of code P1129 refer to chart P1127 Thru P1232 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1130 - P1134, ( P1131 P1132 P1133 1130 1131 1132 1133 1134 ) > System Information > System Diagnosis > P1130 P1130 - P1134: Testing and Inspection P1130 For diagnosis of code P1130 refer to chart P1127 Thru P1232 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1130 - P1134, ( P1131 P1132 P1133 1130 1131 1132 1133 1134 ) > System Information > System Diagnosis > P1130 > Page 403 P1130 - P1134: Testing and Inspection P1131 For diagnosis of code P1131 refer to chart P1127 Thru P1232 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1130 - P1134, ( P1131 P1132 P1133 1130 1131 1132 1133 1134 ) > System Information > System Diagnosis > P1130 > Page 404 P1130 - P1134: Testing and Inspection P1132 For diagnosis of code P1132 refer to chart P1127 Thru P1232 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1135 - P1139, ( P1136 P1137 P1138 1135 1136 1137 1138 1139 ) > System Information > System Diagnosis > P1137 P1135 - P1139: Testing and Inspection P1137 For diagnosis of code P1137 refer to chart P1127 Thru P1232 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1135 - P1139, ( P1136 P1137 P1138 1135 1136 1137 1138 1139 ) > System Information > System Diagnosis > P1137 > Page 409 P1135 - P1139: Testing and Inspection P1138 For diagnosis of code P1138 refer to chart P1127 Thru P1232 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1150 - P1154, ( P1151 P1152 P1153 1150 1151 1152 1153 1154 ) > System Information > System Diagnosis > P1150 P1150 - P1154: Testing and Inspection P1150 For diagnosis of code P1150 refer to chart P1127 Thru P1232 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1150 - P1154, ( P1151 P1152 P1153 1150 1151 1152 1153 1154 ) > System Information > System Diagnosis > P1150 > Page 414 P1150 - P1154: Testing and Inspection P1151 For diagnosis of code P1151 refer to chart P1127 Thru P1232 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1150 - P1154, ( P1151 P1152 P1153 1150 1151 1152 1153 1154 ) > System Information > System Diagnosis > P1150 > Page 415 P1150 - P1154: Testing and Inspection P1152 For diagnosis of code P1152 refer to chart P1127 Thru P1232 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1155 - P1159, ( P1156 P1157 P1158 1155 1156 1157 1158 1159 ) > System Information > System Diagnosis > P1157 P1155 - P1159: Testing and Inspection P1157 For diagnosis of code P1157 refer to chart P1127 Thru P1232 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1155 - P1159, ( P1156 P1157 P1158 1155 1156 1157 1158 1159 ) > System Information > System Diagnosis > P1157 > Page 420 P1155 - P1159: Testing and Inspection P1158 For diagnosis of code P1158 refer to chart P1127 Thru P1232 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1165 - P1169, ( P1166 P1167 P1168 1165 1166 1167 1168 1169 ) > System Information > System Diagnosis > P1168 P1165 - P1169: Testing and Inspection P1168 For diagnosis of code P1168 refer to chart P1127 Thru P1232 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1165 - P1169, ( P1166 P1167 P1168 1165 1166 1167 1168 1169 ) > System Information > System Diagnosis > P1168 > Page 425 P1165 - P1169: Testing and Inspection P1169 For diagnosis of code P1169 refer to chart P1127 Thru P1232 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1180 - P1184, ( P1181 P1182 P1183 1180 1181 1182 1183 1184 ) > System Information > System Diagnosis > P1180 P1180 - P1184: Testing and Inspection P1180 For diagnosis of code P1180 refer to chart P1127 Thru P1232 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1180 - P1184, ( P1181 P1182 P1183 1180 1181 1182 1183 1184 ) > System Information > System Diagnosis > P1180 > Page 430 P1180 - P1184: Testing and Inspection P1181 For diagnosis of code P1181 refer to chart P1127 Thru P1232 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1180 - P1184, ( P1181 P1182 P1183 1180 1181 1182 1183 1184 ) > System Information > System Diagnosis > P1180 > Page 431 P1180 - P1184: Testing and Inspection P1183 For diagnosis of code P1183 refer to chart P1127 Thru P1232 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1180 - P1184, ( P1181 P1182 P1183 1180 1181 1182 1183 1184 ) > System Information > System Diagnosis > P1180 > Page 432 P1180 - P1184: Testing and Inspection P1184 For diagnosis of code P1184 refer to chart P1127 Thru P1232 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1225 - P1229, ( P1226 P1227 P1228 1225 1226 1227 1228 1229 ) > System Information > System Diagnosis P1225 - P1229: Testing and Inspection For diagnosis of code P1229 refer to chart P1127 Thru P1232 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1230 - P1234, ( P1231 P1232 P1233 1230 1231 1232 1233 1234 ) > System Information > System Diagnosis > P1232 P1230 - P1234: Testing and Inspection P1232 For diagnosis of code P1232 refer to chart P1127 Thru P1232 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1230 - P1234, ( P1231 P1232 P1233 1230 1231 1232 1233 1234 ) > System Information > System Diagnosis > P1232 > Page 441 P1230 - P1234: Testing and Inspection P1233 For diagnosis of code P1233 refer to chart P1233 Thru P1401 NOTE 10: Perform Rear Electronics Module (REM) self-test/diagnostics. If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1230 - P1234, ( P1231 P1232 P1233 1230 1231 1232 1233 1234 ) > System Information > System Diagnosis > P1232 > Page 442 P1230 - P1234: Testing and Inspection P1234 For diagnosis of code P1234 refer to chart P1233 Thru P1401 NOTE 10: Perform Rear Electronics Module (REM) self-test/diagnostics. If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239, ( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 P1235 - P1239: Testing and Inspection P1235 For diagnosis of code P1235 refer to chart P1233 Thru P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239, ( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 447 P1235 - P1239: Testing and Inspection P1236 For diagnosis of code P1236 refer to chart P1233 Thru P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239, ( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 448 P1235 - P1239: Testing and Inspection P1237 For diagnosis of code P1237 refer to chart P1233 Thru P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239, ( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 449 P1235 - P1239: Testing and Inspection P1238 For diagnosis of code P1238 refer to chart P1233 Thru P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1240 - P1244, ( P1241 P1242 P1243 1240 1241 1242 1243 1244 ) > System Information > System Diagnosis P1240 - P1244: Testing and Inspection For diagnosis of code P1244 refer to chart P1233 Thru P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1245 - P1249, ( P1246 P1247 P1248 1245 1246 1247 1248 1249 ) > System Information > System Diagnosis > P1245 P1245 - P1249: Testing and Inspection P1245 For diagnosis of code P1245 refer to chart P1233 Thru P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1245 - P1249, ( P1246 P1247 P1248 1245 1246 1247 1248 1249 ) > System Information > System Diagnosis > P1245 > Page 457 P1245 - P1249: Testing and Inspection P1246 For diagnosis of code P1246 refer to chart P1233 Thru P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1260 - P1264, ( P1261 P1262 P1263 1260 1261 1262 1263 1264 ) > System Information > System Diagnosis P1260 - P1264: Testing and Inspection For diagnosis of code P1260 refer to chart P1233 Thru P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1270 - P1274, ( P1271 P1272 P1273 1270 1271 1272 1273 1274 ) > System Information > System Diagnosis P1270 - P1274: Testing and Inspection For diagnosis of code P1270 refer to chart P1233 Thru P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1285 - P1289, ( P1286 P1287 P1288 1285 1286 1287 1288 1289 ) > System Information > System Diagnosis > P1285 P1285 - P1289: Testing and Inspection P1285 For diagnosis of code P1285 refer to chart P1233 Thru P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1285 - P1289, ( P1286 P1287 P1288 1285 1286 1287 1288 1289 ) > System Information > System Diagnosis > P1285 > Page 468 P1285 - P1289: Testing and Inspection P1288 For diagnosis of code P1288 refer to chart P1233 Thru P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1285 - P1289, ( P1286 P1287 P1288 1285 1286 1287 1288 1289 ) > System Information > System Diagnosis > P1285 > Page 469 P1285 - P1289: Testing and Inspection P1289 For diagnosis of code P1289 refer to chart P1233 Thru P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1290 - P1294, ( P1291 P1292 P1293 1290 1291 1292 1293 1294 ) > System Information > System Diagnosis P1290 - P1294: Testing and Inspection For diagnosis of code P1290 refer to chart P1233 Thru P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1295 - P1299, ( P1296 P1297 P1298 1295 1296 1297 1298 1299 ) > System Information > System Diagnosis P1295 - P1299: Testing and Inspection For diagnosis of code P1299 refer to chart P1233 Thru P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1305 - P1309, ( P1306 P1307 P1308 1305 1306 1307 1308 1309 ) > System Information > System Diagnosis P1305 - P1309: Testing and Inspection For diagnosis of code P1309 refer to chart P1233 Thru P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1335 - P1339, ( P1336 P1337 P1338 1335 1336 1337 1338 1339 ) > System Information > System Diagnosis P1335 - P1339: Testing and Inspection For diagnosis of code P1336 refer to chart P1233 Thru P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1380 - P1384, ( P1381 P1382 P1383 1380 1381 1382 1383 1384 ) > System Information > System Diagnosis > P1380 P1380 - P1384: Testing and Inspection P1380 For diagnosis of code P1380 refer to chart P1233 Thru P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1380 - P1384, ( P1381 P1382 P1383 1380 1381 1382 1383 1384 ) > System Information > System Diagnosis > P1380 > Page 487 P1380 - P1384: Testing and Inspection P1381 For diagnosis of code P1381 refer to chart P1233 Thru P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1380 - P1384, ( P1381 P1382 P1383 1380 1381 1382 1383 1384 ) > System Information > System Diagnosis > P1380 > Page 488 P1380 - P1384: Testing and Inspection P1383 For diagnosis of code P1383 refer to chart P1233 Thru P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1400 - P1404, ( P1401 P1402 P1403 1400 1401 1402 1403 1404 ) > System Information > System Diagnosis > P1400 P1400 - P1404: Testing and Inspection P1400 For diagnosis of code P1400 refer to chart P1233 Thru P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1400 - P1404, ( P1401 P1402 P1403 1400 1401 1402 1403 1404 ) > System Information > System Diagnosis > P1400 > Page 494 P1400 - P1404: Testing and Inspection P1401 For diagnosis of code P1401 refer to chart P1233 Thru P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409, ( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 P1405 - P1409: Testing and Inspection P1405 For diagnosis of code P1405 refer to chart P1405 Thru P1501 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409, ( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 499 P1405 - P1409: Testing and Inspection P1406 For diagnosis of code P1406 refer to chart P1405 Thru P1501 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409, ( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 500 P1405 - P1409: Testing and Inspection P1408 For diagnosis of code P1408 refer to chart P1405 Thru P1501 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409, ( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 501 P1405 - P1409: Testing and Inspection P1409 For diagnosis of code P1409 refer to chart P1405 Thru P1501 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1410 - P1414, ( P1411 P1412 P1413 1410 1411 1412 1413 1414 ) > System Information > System Diagnosis > P1413 P1410 - P1414: Testing and Inspection P1413 For diagnosis of code P1413 refer to chart P1405 Thru P1501 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1410 - P1414, ( P1411 P1412 P1413 1410 1411 1412 1413 1414 ) > System Information > System Diagnosis > P1413 > Page 506 P1410 - P1414: Testing and Inspection P1414 For diagnosis of code P1414 refer to chart P1405 Thru P1501 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1430 - P1434, ( P1431 P1432 P1433 1430 1431 1432 1433 1434 ) > System Information > System Diagnosis P1430 - P1434: Testing and Inspection For diagnosis of code P1432 refer to chart P1405 Thru P1501 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1435 - P1439, ( P1436 P1437 P1438 1435 1436 1437 1438 1439 ) > System Information > System Diagnosis > P1436 P1435 - P1439: Testing and Inspection P1436 For diagnosis of code P1436 refer to chart P1405 Thru P1501 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1435 - P1439, ( P1436 P1437 P1438 1435 1436 1437 1438 1439 ) > System Information > System Diagnosis > P1436 > Page 514 P1435 - P1439: Testing and Inspection P1437 For diagnosis of code P1437 refer to chart P1405 Thru P1501 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1440 - P1444, ( P1441 P1442 P1443 1440 1441 1442 1443 1444 ) > System Information > System Diagnosis P1440 - P1444: Testing and Inspection For diagnosis of code P1443 refer to chart DTC Index P1443 - P1450 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Evaporative Emissions diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1450 - P1454, ( P1451 P1452 P1453 1450 1451 1452 1453 1454 ) > System Information > System Diagnosis > P1450 P1450 - P1454: Testing and Inspection P1450 For diagnosis of code P1450 refer to the system experiencing the problem. Computers and Control Systems P1405 Thru P1501 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Evaporative Emissions System Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1450 - P1454, ( P1451 P1452 P1453 1450 1451 1452 1453 1454 ) > System Information > System Diagnosis > P1450 > Page 522 DTC Index P1443 - P1450 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Evaporative Emissions diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1450 - P1454, ( P1451 P1452 P1453 1450 1451 1452 1453 1454 ) > System Information > System Diagnosis > P1450 > Page 523 P1450 - P1454: Testing and Inspection P1451 For diagnosis of code P1451 refer to chart P1405 Thru P1501 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 P1460 - P1464: Testing and Inspection P1460 For diagnosis of code P1460 refer to chart P1405 Thru P1501 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 528 P1460 - P1464: Testing and Inspection P1461 For diagnosis of code P1461 refer to chart P1405 Thru P1501 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 529 P1460 - P1464: Testing and Inspection P1462 For diagnosis of code P1462 refer to chart P1405 Thru P1501 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 530 P1460 - P1464: Testing and Inspection P1463 For diagnosis of code P1463 refer to chart P1405 Thru P1501 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 531 P1460 - P1464: Testing and Inspection P1464 For diagnosis of code P1464 refer to chart P1405 Thru P1501 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1465 - P1469, ( P1466 P1467 P1468 1465 1466 1467 1468 1469 ) > System Information > System Diagnosis P1465 - P1469: Testing and Inspection For diagnosis of code P1469 refer to chart P1405 Thru P1501 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1470 - P1474, ( P1471 P1472 P1473 1470 1471 1472 1473 1474 ) > System Information > System Diagnosis P1470 - P1474: Testing and Inspection For diagnosis of code P1474 refer to chart P1405 Thru P1501 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1475 - P1479, ( P1476 P1477 P1478 1475 1476 1477 1478 1479 ) > System Information > System Diagnosis > P1477 P1475 - P1479: Testing and Inspection P1477 For diagnosis of code P1477 refer to chart P1405 Thru P1501 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1475 - P1479, ( P1476 P1477 P1478 1475 1476 1477 1478 1479 ) > System Information > System Diagnosis > P1477 > Page 542 P1475 - P1479: Testing and Inspection P1479 For diagnosis of code P1479 refer to chart P1405 Thru P1501 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 P1500 - P1504: Testing and Inspection P1500 For diagnosis of code P1500 refer to chart P1405 Thru P1501 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 548 P1500 - P1504: Testing and Inspection P1501 For diagnosis of code P1501 refer to chart P1405 Thru P1501 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 549 P1500 - P1504: Testing and Inspection P1502 For diagnosis of code P1502 refer to chart P1502 Thru P1640 NOTE 12: Vehicle speed information is provided by the Anti-lock Brake System (ABS). If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete ABS diagnosis, See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 550 P1500 - P1504: Testing and Inspection P1504 For diagnosis of code P1504 refer to chart P1502 Thru P1640 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1505 - P1509, ( P1506 P1507 P1508 1505 1506 1507 1508 1509 ) > System Information > System Diagnosis > P1506 P1505 - P1509: Testing and Inspection P1506 For diagnosis of code P1506 refer to chart P1502 Thru P1640 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1505 - P1509, ( P1506 P1507 P1508 1505 1506 1507 1508 1509 ) > System Information > System Diagnosis > P1506 > Page 555 P1505 - P1509: Testing and Inspection P1507 For diagnosis of code P1507 refer to chart P1502 Thru P1640 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519, ( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 P1515 - P1519: Testing and Inspection P1516 For diagnosis of code P1516 refer to chart P1502 Thru P1640 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519, ( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 560 P1515 - P1519: Testing and Inspection P1517 For diagnosis of code P1517 refer to chart P1502 Thru P1640 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519, ( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 561 P1515 - P1519: Testing and Inspection P1518 For diagnosis of code P1518 refer to chart P1502 Thru P1640 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519, ( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 562 P1515 - P1519: Testing and Inspection P1519 For diagnosis of code P1519 refer to chart P1502 Thru P1640 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1520 - P1524, ( P1521 P1522 P1523 1520 1521 1522 1523 1524 ) > System Information > System Diagnosis P1520 - P1524: Testing and Inspection For diagnosis of code P1520 refer to chart P1502 Thru P1640 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1535 - P1539, ( P1536 P1537 P1538 1535 1536 1537 1538 1539 ) > System Information > System Diagnosis > P1537 P1535 - P1539: Testing and Inspection P1537 For diagnosis of code P1537 refer to chart P1502 Thru P1640 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1535 - P1539, ( P1536 P1537 P1538 1535 1536 1537 1538 1539 ) > System Information > System Diagnosis > P1537 > Page 570 P1535 - P1539: Testing and Inspection P1538 For diagnosis of code P1538 refer to chart P1502 Thru P1640 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1545 - P1549, ( P1546 P1547 P1548 1545 1546 1547 1548 1549 ) > System Information > System Diagnosis P1545 - P1549: Testing and Inspection For diagnosis of code P1549 refer to chart P1502 Thru P1640 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1550 - P1554, ( P1551 P1552 P1553 1550 1551 1552 1553 1554 ) > System Information > System Diagnosis P1550 - P1554: Testing and Inspection For diagnosis of code P1550 refer to chart P1502 Thru P1640 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1605 - P1609, ( P1606 P1607 P1608 1605 1606 1607 1608 1609 ) > System Information > System Diagnosis P1605 - P1609: Testing and Inspection For diagnosis of code P1605 refer to chart P1502 Thru P1640 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1630 - P1634, ( P1631 P1632 P1633 1630 1631 1632 1633 1634 ) > System Information > System Diagnosis P1630 - P1634: Testing and Inspection For diagnosis of code P1633 refer to chart P1502 Thru P1640 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639, ( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 P1635 - P1639: Testing and Inspection P1635 For diagnosis of code P1635 refer to chart P1502 Thru P1640 NOTE 11: The Vehicle ID block (VID) needs to be reprogrammed. For instructions refer to the Flash VID Block Procedure, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639, ( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 > Page 588 P1635 - P1639: Testing and Inspection P1636 For diagnosis of code P1636 refer to chart P1502 Thru P1640 NOTE 18: DTC P1636 indicates the PCM has lost communication with the Inductive Signature Chip. Replace PCM. If replacement is necessary refer to Flash Electically Erasable Programmable Read Only Memory (EEPROM), See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639, ( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 > Page 589 P1635 - P1639: Testing and Inspection P1639 For diagnosis of code P1639 refer to chart P1502 Thru P1640 NOTE 11: The Vehicle ID block (VID) needs to be reprogrammed. For instructions refer to the Flash VID Block Procedure, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1640 - P1644, ( P1641 P1642 P1643 1640 1641 1642 1643 1644 ) > System Information > System Diagnosis P1640 - P1644: Testing and Inspection For diagnosis of code P1641 refer to chart P1641 Thru P179x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1650 - P1654, ( P1651 P1652 P1653 1650 1651 1652 1653 1654 ) > System Information > System Diagnosis > P1650 P1650 - P1654: Testing and Inspection P1650 For diagnosis of code P1650 refer to chart P1641 Thru P179x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1650 - P1654, ( P1651 P1652 P1653 1650 1651 1652 1653 1654 ) > System Information > System Diagnosis > P1650 > Page 597 P1650 - P1654: Testing and Inspection P1651 For diagnosis of code P1651 refer to chart P1641 Thru P179x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704, ( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1702 P1700 - P1704: Testing and Inspection P1702 For diagnosis of code P1702 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704, ( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1702 > Page 603 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704, ( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1702 > Page 604 P1700 - P1704: Testing and Inspection P1703 For diagnosis of code P1703 refer to chart P1641 Thru P179x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704, ( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1702 > Page 605 P1700 - P1704: Testing and Inspection P1704 For diagnosis of code P1704 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704, ( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1702 > Page 606 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1705 - P1709, ( P1706 P1707 P1708 1705 1706 1707 1708 1709 ) > System Information > System Diagnosis > P1705 P1705 - P1709: Testing and Inspection P1705 Manual Transmission For diagnosis of code P1705 refer to chart P1641 Thru P179x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Automatic Transmission For diagnosis of code P1705 refer to chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1705 - P1709, ( P1706 P1707 P1708 1705 1706 1707 1708 1709 ) > System Information > System Diagnosis > P1705 > Page 611 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1705 - P1709, ( P1706 P1707 P1708 1705 1706 1707 1708 1709 ) > System Information > System Diagnosis > P1705 > Page 612 P1705 - P1709: Testing and Inspection P1709 For diagnosis of code P1709 refer to chart P1641 Thru P179x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714, ( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1711 P1710 - P1714: Testing and Inspection P1711 For diagnosis of code P1711 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714, ( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1711 > Page 617 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714, ( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1711 > Page 618 P1710 - P1714: Testing and Inspection P1713 For diagnosis of code P1713 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714, ( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1711 > Page 619 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714, ( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1711 > Page 620 P1710 - P1714: Testing and Inspection P1714 For diagnosis of code P1714 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714, ( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1711 > Page 621 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719, ( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 P1715 - P1719: Testing and Inspection P1715 For diagnosis of code P1715 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719, ( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 > Page 626 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719, ( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 > Page 627 P1715 - P1719: Testing and Inspection P1716 For diagnosis of code P1716 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719, ( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 > Page 628 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719, ( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 > Page 629 P1715 - P1719: Testing and Inspection P1717 For diagnosis of code P1717 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719, ( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 > Page 630 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719, ( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 > Page 631 P1715 - P1719: Testing and Inspection P1718 For diagnosis of code P1718 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719, ( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 > Page 632 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1740 - P1744, ( P1741 P1742 P1743 1740 1741 1742 1743 1744 ) > System Information > System Diagnosis P1740 - P1744: Testing and Inspection For diagnosis of code P1740 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1740 - P1744, ( P1741 P1742 P1743 1740 1741 1742 1743 1744 ) > System Information > System Diagnosis > Page 636 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1745 - P1749, ( P1746 P1747 P1748 1745 1746 1747 1748 1749 ) > System Information > System Diagnosis > P1746 P1745 - P1749: Testing and Inspection P1746 For diagnosis of code P1746 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1745 - P1749, ( P1746 P1747 P1748 1745 1746 1747 1748 1749 ) > System Information > System Diagnosis > P1746 > Page 641 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1745 - P1749, ( P1746 P1747 P1748 1745 1746 1747 1748 1749 ) > System Information > System Diagnosis > P1746 > Page 642 P1745 - P1749: Testing and Inspection P1747 For diagnosis of code P1747 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1745 - P1749, ( P1746 P1747 P1748 1745 1746 1747 1748 1749 ) > System Information > System Diagnosis > P1746 > Page 643 - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784, ( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis > P1780 P1780 - P1784: Testing and Inspection P1780 For diagnosis of code P1780 refer to chart P1641 Thru P179x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784, ( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis > P1780 > Page 648 P1780 - P1784: Testing and Inspection P1781 For diagnosis of code P1781 refer to chart P1641 Thru P179x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784, ( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis > P1780 > Page 649 P1780 - P1784: Testing and Inspection P1783 For diagnosis of code P1783 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784, ( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis > P1780 > Page 650 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1900-P19ZZ > P1900 - P1904, ( P1901 P1902 P1903 1900 1901 1902 1903 1904 ) > System Information > System Diagnosis > Manual Transmission P1900 - P1904: Testing and Inspection Manual Transmission For diagnosis of code P1900 refer to chart P18xx Thru P2198, Pxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1900-P19ZZ > P1900 - P1904, ( P1901 P1902 P1903 1900 1901 1902 1903 1904 ) > System Information > System Diagnosis > Manual Transmission > Page 656 P1900 - P1904: Testing and Inspection Automatic Transmission For diagnosis of code P1900 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2195 - P2199, ( P2196 P2197 P2198 2195 2196 2197 2198 2199 ) > System Information > System Diagnosis > P2195 P2195 - P2199: Testing and Inspection P2195 Ford directs the user to follow P1131 For diagnosis of code P2195, refer to P1131 in the following chart P1127 Thru P1232 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2195 - P2199, ( P2196 P2197 P2198 2195 2196 2197 2198 2199 ) > System Information > System Diagnosis > P2195 > Page 662 P2195 - P2199: Testing and Inspection P2196 Ford directs the user to follow P1132 For diagnosis of code P2196, refer to P1132 in the following chart P1127 Thru P1232 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2195 - P2199, ( P2196 P2197 P2198 2195 2196 2197 2198 2199 ) > System Information > System Diagnosis > P2195 > Page 663 P2195 - P2199: Testing and Inspection P2197 Ford directs the user to follow P1151 For diagnosis of code P2197, refer to P1151 in the following chart P1127 Thru P1232 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P2100-P21ZZ > P2195 - P2199, ( P2196 P2197 P2198 2195 2196 2197 2198 2199 ) > System Information > System Diagnosis > P2195 > Page 664 P2195 - P2199: Testing and Inspection P2198 Ford directs the user to follow P1152 For diagnosis of code P2198, refer to P1152 in the following chart P1127 Thru P1232 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations View 151-9 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 670 Alarm Module: Diagrams Connector View C274a Connector View C274b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 671 Alarm Module: Application and ID For further information please see Accessories and Optional Equipment, General Module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Locations View 151-8 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions Multifunction Electronic Control Modules: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. NOTE: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 677 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number or the component name in one of the the A-Z Component Lists, the Component Location description for that component can easily be found. See: Locations/Component Locations/A-Z Component List Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 678 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 679 the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 680 that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 681 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 682 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 683 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 684 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 685 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 686 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 687 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 688 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 689 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 690 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 691 Systems Overview Wire Color Code Identification Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 692 OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 693 Multifunction Electronic Control Modules: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 694 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 695 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 696 Multifunction Electronic Control Modules: Connector Views Connector View C2100a Connector View C2100b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 697 Multifunction Electronic Control Modules: Electrical Diagrams Diagram 59-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 698 Diagram 59-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 699 Diagram 59-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 700 Diagram 59-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Page 701 Multifunction Electronic Control Modules: Service Precautions CAUTION: ^ Prior to removal of the Generic Electronic Module (GEM), it is necessary to upload module configuration information to the diagnostic tool. This information needs to be downloaded into the new module once installed. ^ Once the new module is installed, it is necessary to download module configuration information from the appropriate diagnostic tool into the new module. ^ Prior to removal of the Vehicle Security module, it is necessary to upload module configuration information to the appropriate diagnostic equipment. This information needs to be downloaded into the new module once installed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Description and Operation > System Description Multifunction Electronic Control Modules: Description and Operation System Description Module Controlled Functions NOTE: Prior to removal of the Generic Electronic Module (GEM), it is necessary to upload module configuration information to a diagnostic tool. This information needs to be downloaded into the new module once installed. The multifunction module consists of the following: ^ generic electronic module (GEM) ^ central security module The GEM controls the following features: ^ front wiper and washer ^ rear wiper and washer ^ warning chime ^ illuminated entry and interior lighting ^ driver one-touch down power window (optional) ^ battery saver relay ^ door ajar warning indicator lamp ^ safety belt warning indicator lamp The Remote Anti-theft Personality (RAP)/central security module controls the following features: ^ remote keyless entry ^ computer-operated locks Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Description and Operation > System Description > Page 704 Multifunction Electronic Control Modules: Description and Operation Principles of Operation (How Does It Work?) Generic Electronic Module (Gem) NOTE: Upon installation of a new Generic Electronic Module (GEM), the module must be reconfigured. Refer to Module Communications Network (Information Bus) prior to GEM removal. The GEM receives inputs and delivers outputs to a majority of the electronically controlled features of the vehicle. The GEM constantly monitors the systems under its control and reports a concern in the form of a Diagnostic Trouble Code (DTC). The DTC can be retrieved with a diagnostic tool through the ISO 9141 communication network. The GEM controls the following features: ^ front wiper and washer ^ warning chime ^ battery saver ^ illuminated entry and interior lighting ^ driver one-touch down power window (optional) ^ door ajar warning indicator lamp ^ safety belt warning indicator lamp Vehicle Security Module The central security module controls the following features: ^ remote keyless entry system ^ computer-operated lock system Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Multifunction Electronic Control Modules: Initial Inspection and Diagnostic Overview Generic Electronic Module (GEM) 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Central Junction Box (CJB) fuse: 10 (7.5A) - 20 (7.5A) - 25 (7.5A) - 28 (7.5A) ^ Wiring harness ^ Connector(s) ^ Circuitry 3. If the concern remains after the inspection, connect the diagnostic tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool manual. 5. Carry out the DATA LINK DIAGNOSTICS test. If the diagnostic tool responds with: ^ CKT914, CKT95 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network (Information Bus). ^ NO RESPONSE/NOT EQUIP for GEM, go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM. 6. If the DTCs retrieved are related to the concern, go to the Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Tests and Associated Procedures 7. If no DTCs related to the concern are retrieved, refer to the appropriate vehicle system to continue diagnostics. Vehicle Security Module (VSM) 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Central Junction Box (CJB) fuse: 18 (25A) - 11 (7.5A) ^ Wiring harness ^ Connector(s) ^ Circuitry 3. If the concern remains after the inspection, connect the diagnostic tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool manual. 5. Carry out the DATA LINK DIAGNOSTICS test. If the diagnostic tool responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network (Information Bus). ^ NO RESPONSE/NOT EQUIP for central security module, go to Pinpoint Test B. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry Out self-test diagnostics for the central security module. 6. If the DTCs retrieved are related to the concern, go to the Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Tests and Associated Procedures 7. If no DTCs related to the concern are retrieved, refer to the appropriate vehicle system to continue diagnostics. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 707 Multifunction Electronic Control Modules: Diagnostic Trouble Code Tests and Associated Procedures DTC Chart B1213 - B1325 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 708 DTC Index B1330 - B1345 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 709 DTC Index B1347 - B1446 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 710 DTC Index B1450 - B1611 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 711 DTC Index B1614 - B1934 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 712 DTC Index B1935 - B2440 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 713 DTC Index B2441 - B2477 DTC Index B2477 - P0500 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 714 DTC Index P1804 - U2018 .. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 715 Multifunction Electronic Control Modules: Symptom Related Diagnostic Procedures Symptom Chart Symptom Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 716 Multifunction Electronic Control Modules: Pinpoint Tests A1 - A2 A2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 717 B1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 718 B1 - B2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Generic Electronic Module (GEM) Multifunction Electronic Control Modules: Service and Repair Generic Electronic Module (GEM) REMOVAL 1. Disconnect the battery ground cable. CAUTION: Prior to removal of the Generic Electronic Module (GEM), it is necessary to upload module configuration information to the diagnostic tool. This information needs to be downloaded into the new module once installed. 2. Remove the radio chassis. 3. Remove the center instrument panel finish panel. 1 Remove the screws. 2 Remove the center instrument panel finish panel. ^ Disconnect the electrical connectors. 4. Remove the GEM. 1 Remove the bolt. 2 Disconnect the electrical connectors from the GEM. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Once the new module is installed, it is necessary to download module configuration information from the appropriate diagnostic tool into the new module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Generic Electronic Module (GEM) > Page 721 Multifunction Electronic Control Modules: Service and Repair Vehicle Security Module REMOVAL CAUTION: Prior to removal of the module, it is necessary to upload module configuration information to the appropriate diagnostic equipment. This information needs to be downloaded into the new module once installed. 1. Disconnect the battery ground cable. 2. Remove the LH rear quarter trim panel. 3. Disconnect the electrical connectors. 4. Remove the central security module. 1 Remove the bolts. 2 Remove the central security module. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Page 722 Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Application and ID Keyless Entry Module: Application and ID For further information please see Accessories and Optional Equipment, General Module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Application and ID Keyless Entry Module: Application and ID For further information please see Accessories and Optional Equipment, General Module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Application and ID Power Door Lock Control Module: Application and ID For further information please see Accessories and Optional Equipment, General Module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations View 151-16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 736 Connector View C921 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications Electronic Brake Control Module: Specifications Control module bolts ............................................................................................................................ ................................................ 1.5 Nm (13 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 741 View 151-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 742 Connector View C135 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 743 Electronic Brake Control Module: Service and Repair Module-Anti-Lock Brake Control Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the electrical connectors. 3. Remove the anti-lock brake control module. 1 Remove the bolts. 2 Remove the anti-lock brake control module. 4. CAUTION: Once the new module is installed, the module configuration information may have to be entered. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 744 To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations Blower Motor Relay: Locations Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 749 Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 750 Connector View C1011 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 751 Blower Motor Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 752 Relay - Micro ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 756 Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 757 Connector View C1008 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 758 Compressor Clutch Relay: Description and Operation Wide Open Throttle A/C Cut-Off The wide open throttle A/C cutoff relay (may be referred to as the A/C clutch relay) is normally open. There is no direct electrical connection between the A/C switch or EATC Module and the A/C clutch. The PCM will receive a signal indicating that A/C is requested (for some applications, this message is sent through the BUS + and BUS - circuits). When A/C is requested, the PCM will check other A/C related inputs that are available (such as ACP (SW), A/C Cycling Switch (ACCS)). If these inputs indicate A/C operation is OK, and the engine conditions are OK (such as coolant temperature, engine rpm, throttle position), the PCM will ground the Wide Open Throttle A/C (WAC) output, closing the relay contacts and sending voltage to the A/C clutch. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 759 Compressor Clutch Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 760 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations Condenser Fan Motor Relay: Locations Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 764 Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 765 Connector View C1056 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 766 Condenser Fan Motor Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 767 Relay - Micro ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Application and ID Audible Warning Device Control Module: Application and ID For further information please see Accessories and Optional Equipment, General Module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 780 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 781 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 782 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 788 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 789 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 790 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Panel Illumination Control Module > Component Information > Locations View 151-9 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Panel Illumination Control Module > Component Information > Locations > Page 794 Panel Illumination Control Module: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Panel Illumination Control Module > Component Information > Locations > Page 795 Instrument Panel Dimming Module, Interior Lamps Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations Battery Discharge Protection Relay: Locations Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 800 Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 801 Connector View C2048 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 802 Battery Discharge Protection Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 803 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations Courtesy Lamp Relay: Locations Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations > Page 807 Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations > Page 808 Connector View C2022 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations > Page 809 Courtesy Lamp Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations > Page 810 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations View 151-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 814 Connector View C1030 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 815 Daytime Running Lamp Control Unit: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the Daytime Running Lamps (DRL) control module. 1 Disconnect the electrical connector. 2 Remove the bolts. 3 Remove the module. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Fog Lamp Relay Fog/Driving Lamp Relay: Locations Fog Lamp Relay Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Fog Lamp Relay > Page 820 Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Fog Lamp Relay > Page 821 Fog/Driving Lamp Relay: Locations Fog Lamp Isolation Relay Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Fog Lamp Relay > Page 822 Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Fog Lamp Relay Connector View C1007 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Fog Lamp Relay > Page 825 Connector View C1038 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Page 826 Fog/Driving Lamp Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Page 827 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Autolamp Headlamp Relay View 151-8 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Autolamp Headlamp Relay > Page 832 Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Autolamp Headlamp Relay Connector View C2233 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Autolamp Headlamp Relay > Page 835 Connector View C2234 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Testing and Inspection > Micro ISO Relay Headlamp Relay: Testing and Inspection Micro ISO Relay Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Testing and Inspection > Micro ISO Relay > Page 838 Relay - Micro ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Testing and Inspection > Micro ISO Relay > Page 839 Headlamp Relay: Testing and Inspection Mini ISO Relay Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Testing and Inspection > Micro ISO Relay > Page 840 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 844 Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 845 Connector View C1006 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 846 Horn Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 847 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Auxiliary Relay Box 2 Relay ID - Before 2/18/02 Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Auxiliary Relay Box 2 Relay ID - Before 2/18/02 > Page 852 Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Parking Lamp Relay: Locations Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 856 Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 857 View 151-8 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 858 Parking Lamp Relay: Diagrams Connector View C1095 Connector View C2059 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 859 Parking Lamp Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 860 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations Trailer Lighting Relay: Locations Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 864 Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 865 Connector View C2049 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 866 Trailer Lighting Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 867 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Locations Turn Signal Relay: Locations Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Locations > Page 871 Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Locations > Page 872 Connector View C2047 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Locations > Page 873 Turn Signal Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Locations > Page 874 Relay - Micro ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 879 Relay - Micro ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 883 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Power Distribution Relay: Locations Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 887 Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 888 Connector View C2049 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 889 Power Distribution Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 890 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Protection Relay > Component Information > Locations > Auxiliary Relay Box 2 Relay ID - Before 2/18/02 Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Protection Relay > Component Information > Locations > Auxiliary Relay Box 2 Relay ID - Before 2/18/02 > Page 895 Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 900 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 901 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 902 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 903 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 904 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 905 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 906 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 907 Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 908 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 909 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 910 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 911 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 912 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 913 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 914 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 915 Relay Box: Locations Auxiliary Relay Box 1 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 916 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 917 Relay Box: Locations Auxiliary Relay Box 2 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 918 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 921 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 922 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 923 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 924 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 925 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 926 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 927 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 928 Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 929 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 930 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 931 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 932 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 933 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 934 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 935 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 936 Relay Box: Application and ID Auxiliary Relay Box 1 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 937 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 938 Relay Box: Application and ID Auxiliary Relay Box 2 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 939 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 950 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 951 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 952 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures Powertrain Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 958 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 959 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 964 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 965 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 966 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 02-8-3 > Apr > 02 > A/T 5R44E/5R55E Fluid Leak at Servo Cover Powertrain Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 02-8-3 > Apr > 02 > A/T 5R44E/5R55E Fluid Leak at Servo Cover > Page 972 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 02-8-3 > Apr > 02 > A/T 5R44E/5R55E Fluid Leak at Servo Cover > Page 973 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 974 View 151-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 975 Powertrain Control Module: Diagrams Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 976 Part 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 977 Powertrain Control Module: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the Powertrain Control Module (PCM) electrical connector. 3. Remove the nuts and the PCM cover. 4. Remove the PCM. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Powertrain Control Module Power Relay: Locations Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 981 Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 982 Connector View C1016 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 983 Powertrain Control Module Power Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 984 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Emission Control Systems > Air Injection Pump Relay > Component Information > Description and Operation Air Injection Pump Relay: Description and Operation Solid State Relay Solid State Relay The solid state relay (Figure 124) switches the high current required for operation of the electric AIR pump. Input control to the solid state relay comes from the powertrain control module (PCM). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Description and Operation Fuel Pump Control Unit: Description and Operation Fuel Pump Driver Module Applications Fuel Pump Driver Module Duty Cycle Signals The Fuel Pump Driver Module (FPDM) communicates diagnostic information to the powertrain control module (PCM) through the Fuel Pump Monitor (FPM) circuit. This information is sent by the FPDM as a duty cycle signal. The three duty cycle signals that may be sent are listed in the table. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 996 Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 997 Connector View C1051 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 998 Fuel Pump Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 999 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Powertrain Control Module Power Relay: Locations Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1003 Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1004 Connector View C1016 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1005 Powertrain Control Module Power Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1006 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs Air Bag Control Module: Technical Service Bulletins Restraints - Control Module DTCs & Associated Fault PIDs TSB 07-12-3 06/25/07 RCM FAULT REPORTING USING DTCS AND BIT-MAPPED PARAMETER IDENTIFIERS (PIDS) - SERVICE TIPS FORD: 2001-2007 Crown Victoria 2002-2007 Taurus 2004-2007 Focus 2005-2007 Five Hundred, Freestyle, Mustang 2006-2007 Fusion 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac 2002-2003 Windstar 2002-2007 Explorer 2003-2007 Expedition 2004-2007 F-150, Freestar 2005-2007 Escape Hybrid, Escape 2007 E-Series LINCOLN: 2001-2007 Town Car 2003-2006 Lincoln LS 2006 Zephyr 2007 MKZ 2003-2005 Aviator 2003-2007 Navigator 2006-2007 Mark LT MERCURY: 2001-2007 Grand Marquis 2002-2005 Sable 2005-2007 Montego 2006-2007 Milan 2002-2007 Mountaineer 2004-2007 Monterey 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 07-7-8 to update the vehicle application. ISSUE Various 2001-2007 vehicles are equipped with a restraints control module (RCM) that report diagnostic trouble codes (DTCs) which provide general fault information. These DTCs require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific fault. Most 2001-2006 Workshop Manuals (WSM) were written using New Generation STAR Tester (NGS) terminology and navigation which does not translate well when using Integrated Diagnostic System (IDS), Portable Diagnostic Software (PDS) or Worldwide Diagnostic System (WDS). ACTION Refer to the Service Tips to assist with navigation of both the WSM and the scan tool being used. SERVICE TIPS DTCs And Associated Fault PIDs Description Many of the continuous memory and on-demand DTCs that can be present in the RCM provide general fault information and require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific concern. DTCs that use fault PIDs are conceptually different from conventional DTCs. Conventional DTCs identify a specific concern for a given component and point to a particular diagnostic path. In the diagnostic path, PIDs are sometimes used to determine the root cause. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 1012 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 1013 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 1014 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 1015 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 1016 DTCs that use fault PIDs do not identify the specific concern. The DTC identifies the component(s) or type of component(s) in which the concern exists. The next level, fault PIDs, identifies the specific device and fault condition. Fault PIDs are available for both on-demand (active) and continuous memory (historic or intermittent) DTCs. A scan tool must be used to view the DTCs and their fault PIDs. The table lists those DTCs that are supported by associated fault PIDs. (Figures 1-5) VIEWING FAULT PIDS USING SCAN TOOLS WSM Direction to FLAG DTC/View Fault PIDs The information in viewing fault PIDs in the WSM has evolved over the years as the scan tools have transitioned. Examples of how the WSM may direct you to view fault PIDs are: ^ FLAG DTC XXXXX/Record All Flagged Faults (2001-2006 WS Ms) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 1017 ^ View and Record DTC XXXXX Fault PIDs (2007 WSM) ^ DataLogger/View and Record DTC XXXXX Fault Pids (2008 and future WSMs) In each instance the direction is the same (view fault PIDs to identify the specific component and fault condition) but how they are accessed by the scan tools, as well as the scan tool terminology, will vary. FLAG the DTC - View the Fault PIDs For example, the "Flag" DTC feature is specific to NGS/NGS+. When using IDS/PDS it is necessary to view the fault PIDs from DataLogger. Using IDS/PDS NOTE WHEN USING IDS/PDS, MOVE THE CURSOR OVER THE PID OR SELECT THE PID TO DISPLAY ITS DEFINITION AT THE BOTTOM OF THE SCREEN. WHEN USING PDS, HIGHLIGHT OR MOVE THE STYLUS OVER THE PID TO SEE THE PID DEFINITION. 1. Perform a self test of the RCM and/or OCS module to retrieve on-demand and continuous memory DTCs. 2. To view the fault PIDs associated with an on-demand DTC: a. Toolbox b. DataLogger c. Modules d. RCM 3. Monitor all "_OD" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". ^ For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_OD PID reads "FAULT' indicating a front internal crash sensor fault. 4. To view the fault PIDs associated with a continuous memory DTC: a. Toolbox b. DataLogger c. Modules d. RCM 5. Monitor all "_CM" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_CM PID reads "FAULT" indicating a front internal crash sensor fault. IDS/PDS Fault PID Naming Conventions The fault PIDs as displayed on IDS/PDS uses a strategy associating it with the DTC. For example, the fault PIDs 2296_18_OD and 2296_18_CM break down as follows: ^ 2296 - The DTC number minus the "B" (body) or "C" (chassis) designation. ^ 18 - An identifier used to distinguish between each of the fault PIDs associated with the DTC. ^ OD - Identifies the fault PID as an on-demand fault. ^ CM - Identifies the fault PID as a continuous memory (intermittent) fault. NOTE THE DTCS AND FAULT PIDS SUPPORTED BY A VEHICLE WILL VARY DEPENDING ON VEHICLE EQUIPMENT. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 1018 Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5) WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 1019 Torque Specifications Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 1020 View 151-9 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 1021 Air Bag Control Module: Diagrams Connector View C2041a Connector View C2041b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Technician Safety Information Air Bag Control Module: Technician Safety Information WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE AND AT THE BEGINNING OF THE REMOVAL PROCEDURE. Refer to Air Bag(s) Arming and Disarming. ^ THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Technician Safety Information > Page 1024 Air Bag Control Module: Vehicle Damage Warnings CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Page 1025 Air Bag Control Module: Description and Operation The Restraints Control Module (RCM) carries out the following functions: ^ signals the inflators to deploy the air bags in the event of a deployable crash. ^ monitors the air bag Supplemental Restraint System (SRS) for faults. ^ illuminates the air bag indicator if a fault is detected. ^ flashes the air bag indicator to indicate the Lamp Fault Code (LFC) detected. ^ communicates through the Data Link Connector (DLC) the current or historical Diagnostic Trouble Codes (DTCs). ^ signals the Generic Electronic Module (GEM) to activate a chime if the air bag indicator is not available and another SRS fault exists. NOTE: The safety sensor is internal to the RCM and is not serviced separately. The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the RUN position, the RCM will flash the air bag indicator located in the instrument cluster. When the ignition is cycled (turned off and then on), the air bag indicator will prove out by lighting for six seconds and then off for two seconds. After the prove out, the air bag indicator will then flash the two-digit LFC for any current SRS fault. If an SRS fault exists, the air bag indicator will flash the LFC five times, and then remain illuminated for the rest of the key cycle. The RCM will also communicate the current and historical DTCs through the DLC, to the scan tool. If the air bag indicator does not function, and the system detects a fault condition, the RCM will signal the GEM to activate an audible chime. The chime is a series of five sets of five tone bursts. If the chime is heard, the SRS and the air bag indicator require repair. LFCs are prioritized. If two or more faults occur at the same time, the fault having the highest priority will be displayed. After that fault has been corrected, the next highest priority fault will be displayed. The RCM includes a backup power supply. This feature provides sufficient backup power to deploy the air bags in the event that the ignition circuit is damaged in a collision before the safing and air bag sensors determine that a deployment is required. The backup power supply will deplete its stored energy approximately one minute after the battery ground cable is disconnected. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Page 1026 Air Bag Control Module: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Air Bag Systems; Testing and Inspection. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module (RCM) Air Bag Control Module: Service and Repair Restraints Control Module (RCM) SPECIAL TOOL(S) REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. All vehicles 1. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Deactivate the Supplemental Restraint System (SRS). Refer to Air Bag(s) Arming and Disarming. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. Refer to Air Bag(s) Arming and Disarming. Vehicles with seat side air bags and power driver seat 3. Connect the battery ground cable. Vehicles with seat side air bags 4. Move the front seats rearward. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module (RCM) > Page 1029 Vehicles with seat side air bags and power driver seat 5. Disconnect the battery ground cable and wait at least one minute. Vehicles with full floor console 6. Remove the full floor console. Vehicles with a restraints control module cover 7. Remove the mat, the screws and the Restraints Control Module (RCM) cover. All vehicles 8. Remove the right-hand side RCM retaining bolts. 9. Remove the RCM. 1 Slide and disengage the two RCM electrical connector locking clips. 2 Push down to pivot the RCM electrical connector tabs and pull out to disconnect. 3 Remove the retaining bolt. 4 Remove the RCM. INSTALLATION WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, CAUTIONS AND NOTES AT THE BEGINNING OF THE REMOVAL PROCEDURE. All vehicles 1. Position the RCM to the center tunnel area and install the three bolts hand-tight. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module (RCM) > Page 1030 NOTE: Make sure the battery ground cable is still disconnected before proceeding with the installation portion of this procedure. 2. Tighten the right-hand side RCM bolts to specification. WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 3. Connect the RCM. 1 Tighten the bolt to specification. 2 Connect the RCM electrical connectors. 3 Slide and engage the RCM electrical connector locking clips. WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 4. Connect the battery ground cable. 5. With the restraint system diagnostic tools still installed at all deployable devices, prove out the air bag system. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 6. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Vehicles with full floor console 7. Install the full floor console. Vehicles with a restraint control module cover Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module (RCM) > Page 1031 8. Position the RCM cover. Install the screws and the mat. Vehicles with seat side air bags and power driver seat 9. Connect the battery ground cable. Vehicles with seat side air bags 10. Move and tilt the front seats to their highest and most forward position. Vehicles with seat side air bags and power driver seat 11. Disconnect the battery ground cable and wait at least one minute. All vehicles 12. Reactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. Refer to Air Bag(s) Arming and Disarming. 13. With all the diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module (RCM) > Page 1032 Air Bag Control Module: Service and Repair Weld Nut Repair "J" Nut, Restraints Control Module (RCM) and Side Impact Sensor WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both this procedures and Weld Nut Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Impact Sensor before proceeding with the repair. ^ If two or more weld nuts are missing, do not install the "J" nuts as outlined in this procedure. Weld nuts must be installed as outlined in Weld Nut Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Impact Sensor. ^ The following procedure applies to vehicles that have a rectangular hole in the sheet metal that is in close proximity to the missing weld nut. 1. Obtain a "J" nut (part number N623332-S301) or any of the following optional "J" nuts (part numbers: N623342-S101, N800854-S100, N800925-S100). 2. Obtain a 6 mm (0.24 in) grounding screw or equivalent. 3. Install the "J,' nut through the rectangular hole in the sheet metal. 4. Install the crash sensor. NOTE: Be sure the threaded portion of the "J" nut is aligned with the clearance hole in the sheet metal. 5. Tighten the attaching screws to specification. Refer to Torque Specifications. Missing Weld Nut, RCM and Side Impact Sensor WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both this procedure and Weld Nut Repair - "J" Nut, Restraints Control Module (RCM) and Side Impact Sensor before proceeding with the repair. ^ Use only this procedure if two or more weld nuts are missing, do not install the "J" nuts as outlined in Weld Nut Repair - "J" Nut, Restraints Control Module (RCM) and Side Crash Sensor. ^ Radiator support repair shown, others are similar. 1. Obtain a 6 mm (0.24 in) weld nut. 2. Obtain a 6 mm (0.24 in) grounding screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module (RCM) > Page 1033 3. Route a sufficient length of copper welding wire through the weld nut clearance hole and back out an adjacent access hole. 4. Feed the copper welding wire through the weld nut, then through a standard flat washer. 5. Secure the flat washer so that it cannot he pulled off the end of the copper welding wire. 6. Pull the copper welding wire back through the clearance hole, allowing the weld nut and flat washer to follow the copper welding wire through. 7. Position the weld nut to the weld nut clearance hole, firmly pulling on the copper welding wire allowing the secured flat washer to hold the weld nut in position. 8. Holding the weld nut securely in place and using a MIG welder, weld in four places around the edge of the weld nut. 9. Metal finish as required. 10. Verify the nut is securely in place. 11. In stall the crash sensor. 12. Tighten the attaching screws to specification. Refer to Torque Specifications. Stripped Weld Nut, RCM and Side Impact Sensor WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 1. Obtain an 8 mm (0.32 in) grounding screw. 2. Drill out the internal threads of the stripped-out weld nut to 7.37 mm (0.29 in) using a letter "L" size drill bit. 3. Position the crash sensor to the vehicle. 4. Install the 8 mm (0.32 in) grounding screw into the drilled-out weld nut. 5. Install the remaining attaching screws. 6. Tighten the attaching screws to specification. Refer to Torque Specifications. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Page 1034 Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs Seat Belt Control Module: Technical Service Bulletins Restraints - Control Module DTCs & Associated Fault PIDs TSB 07-12-3 06/25/07 RCM FAULT REPORTING USING DTCS AND BIT-MAPPED PARAMETER IDENTIFIERS (PIDS) - SERVICE TIPS FORD: 2001-2007 Crown Victoria 2002-2007 Taurus 2004-2007 Focus 2005-2007 Five Hundred, Freestyle, Mustang 2006-2007 Fusion 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac 2002-2003 Windstar 2002-2007 Explorer 2003-2007 Expedition 2004-2007 F-150, Freestar 2005-2007 Escape Hybrid, Escape 2007 E-Series LINCOLN: 2001-2007 Town Car 2003-2006 Lincoln LS 2006 Zephyr 2007 MKZ 2003-2005 Aviator 2003-2007 Navigator 2006-2007 Mark LT MERCURY: 2001-2007 Grand Marquis 2002-2005 Sable 2005-2007 Montego 2006-2007 Milan 2002-2007 Mountaineer 2004-2007 Monterey 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 07-7-8 to update the vehicle application. ISSUE Various 2001-2007 vehicles are equipped with a restraints control module (RCM) that report diagnostic trouble codes (DTCs) which provide general fault information. These DTCs require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific fault. Most 2001-2006 Workshop Manuals (WSM) were written using New Generation STAR Tester (NGS) terminology and navigation which does not translate well when using Integrated Diagnostic System (IDS), Portable Diagnostic Software (PDS) or Worldwide Diagnostic System (WDS). ACTION Refer to the Service Tips to assist with navigation of both the WSM and the scan tool being used. SERVICE TIPS DTCs And Associated Fault PIDs Description Many of the continuous memory and on-demand DTCs that can be present in the RCM provide general fault information and require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific concern. DTCs that use fault PIDs are conceptually different from conventional DTCs. Conventional DTCs identify a specific concern for a given component and point to a particular diagnostic path. In the diagnostic path, PIDs are sometimes used to determine the root cause. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 1039 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 1040 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 1041 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 1042 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 1043 DTCs that use fault PIDs do not identify the specific concern. The DTC identifies the component(s) or type of component(s) in which the concern exists. The next level, fault PIDs, identifies the specific device and fault condition. Fault PIDs are available for both on-demand (active) and continuous memory (historic or intermittent) DTCs. A scan tool must be used to view the DTCs and their fault PIDs. The table lists those DTCs that are supported by associated fault PIDs. (Figures 1-5) VIEWING FAULT PIDS USING SCAN TOOLS WSM Direction to FLAG DTC/View Fault PIDs The information in viewing fault PIDs in the WSM has evolved over the years as the scan tools have transitioned. Examples of how the WSM may direct you to view fault PIDs are: ^ FLAG DTC XXXXX/Record All Flagged Faults (2001-2006 WS Ms) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 1044 ^ View and Record DTC XXXXX Fault PIDs (2007 WSM) ^ DataLogger/View and Record DTC XXXXX Fault Pids (2008 and future WSMs) In each instance the direction is the same (view fault PIDs to identify the specific component and fault condition) but how they are accessed by the scan tools, as well as the scan tool terminology, will vary. FLAG the DTC - View the Fault PIDs For example, the "Flag" DTC feature is specific to NGS/NGS+. When using IDS/PDS it is necessary to view the fault PIDs from DataLogger. Using IDS/PDS NOTE WHEN USING IDS/PDS, MOVE THE CURSOR OVER THE PID OR SELECT THE PID TO DISPLAY ITS DEFINITION AT THE BOTTOM OF THE SCREEN. WHEN USING PDS, HIGHLIGHT OR MOVE THE STYLUS OVER THE PID TO SEE THE PID DEFINITION. 1. Perform a self test of the RCM and/or OCS module to retrieve on-demand and continuous memory DTCs. 2. To view the fault PIDs associated with an on-demand DTC: a. Toolbox b. DataLogger c. Modules d. RCM 3. Monitor all "_OD" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". ^ For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_OD PID reads "FAULT' indicating a front internal crash sensor fault. 4. To view the fault PIDs associated with a continuous memory DTC: a. Toolbox b. DataLogger c. Modules d. RCM 5. Monitor all "_CM" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_CM PID reads "FAULT" indicating a front internal crash sensor fault. IDS/PDS Fault PID Naming Conventions The fault PIDs as displayed on IDS/PDS uses a strategy associating it with the DTC. For example, the fault PIDs 2296_18_OD and 2296_18_CM break down as follows: ^ 2296 - The DTC number minus the "B" (body) or "C" (chassis) designation. ^ 18 - An identifier used to distinguish between each of the fault PIDs associated with the DTC. ^ OD - Identifies the fault PID as an on-demand fault. ^ CM - Identifies the fault PID as a continuous memory (intermittent) fault. NOTE THE DTCS AND FAULT PIDS SUPPORTED BY A VEHICLE WILL VARY DEPENDING ON VEHICLE EQUIPMENT. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 1045 Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5) WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 1050 Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 1051 Connector View C1017 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 1052 Starter Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 1053 Relay - Micro ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations View 151-9 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 1058 Connector View C2021 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 1059 Heated Glass Element Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 1060 Relay - Micro ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Application and ID Power Window Control Module: Application and ID For further information please see Accessories and Optional Equipment, General Module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Window Safety Relay Power Window Relay: Locations Window Safety Relay Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Window Safety Relay > Page 1068 Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Window Safety Relay > Page 1069 Power Window Relay: Locations One-Touch Window Relay Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Window Safety Relay > Page 1070 Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Window Safety Relay Power Window Relay: Diagrams Window Safety Relay Connector View C1096 Connector View C2058 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Window Safety Relay > Page 1073 Connector View C2051 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > Micro ISO Relay Power Window Relay: Testing and Inspection Micro ISO Relay Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > Micro ISO Relay > Page 1076 Relay - Micro ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > Micro ISO Relay > Page 1077 Power Window Relay: Testing and Inspection Mini ISO Relay Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > Micro ISO Relay > Page 1078 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Application and ID Windshield Washer Control Module: Application and ID For further information please see Accessories and Optional Equipment, General Module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations Windshield Washer Relay: Locations Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 1086 Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 1087 Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Windshield Washer Relay Connector View C1004 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Windshield Washer Relay > Page 1090 Connector View C1039 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Page 1091 Windshield Washer Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Page 1092 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Application and ID Wiper Control Module: Application and ID For further information please see Accessories and Optional Equipment, General Module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay Wiper Relay: Locations Wiper High/Low Relay Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 1100 Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 1101 Wiper Relay: Locations Wiper Run/Park Relay Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 1102 Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Wiper High/Low Relay Connector View C1001 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Wiper High/Low Relay > Page 1105 Connector View C1002 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Wiper High/Low Relay > Page 1106 Connector View C1036 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Wiper High/Low Relay > Page 1107 Connector View C1037 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Wiper High/Low Relay > Page 1108 Connector View C1059 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Page 1109 Wiper Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Page 1110 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Driver Side Connector View C505 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Driver Side > Page 1117 Connector View C605 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Driver Side Power Door Lock Switch: Testing and Inspection Driver Side Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Driver Side > Page 1120 Door Lock Switch, Driver Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Driver Side > Page 1121 Power Door Lock Switch: Testing and Inspection Passenger Side Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Driver Side > Page 1122 Door Lock Switch, Passenger Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams Connector View C527 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Page 1126 Power Mirror Switch: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Page 1127 Exterior Rear View Mirror Switch Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Page 1128 Exterior Rear View Mirror Switch Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams Power Seat Switch: Diagrams Connector View C360 Connector View C369 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service Precautions > Technician Safety Information Power Seat Switch: Technician Safety Information WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTER HANDLING AN AIR BAG MODULE. - NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. - TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). - TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE AND IN THE FRONT SEAT REMOVAL AND INSTALLATION PROCEDURE. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service Precautions > Technician Safety Information > Page 1134 Power Seat Switch: Vehicle Damage Warnings CAUTION: - To prevent damage to the side shield, the clips must be depressed in order to release the side shield from the cushion pan. - Use care when disconnecting the seat cushion side shield from the seat cushion frame so the tabs on the seat cushion side shield are not damaged. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > With Side Air Bags Power Seat Switch: Testing and Inspection With Side Air Bags Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > With Side Air Bags > Page 1137 Seat Adjust Switch, With Side Air Bags Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > With Side Air Bags > Page 1138 Power Seat Switch: Testing and Inspection Without Side Air Bags Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > With Side Air Bags > Page 1139 Seat Adjust Switch, Without Side Air Bags Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch - With Side Air Bag Power Seat Switch: Service and Repair Seat Control Switch - With Side Air Bag Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTER HANDLING AN AIR BAG MODULE. - NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. 1. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Deactivate the supplemental restraint system (SRS). WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. 3. Remove the front seat. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE FRONT SEAT REMOVAL AND INSTALLATION PROCEDURE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch - With Side Air Bag > Page 1142 4. Remove the lumbar support knob. 5. Remove the rear side shield screw. 6. Release the side shield clips. CAUTION: To prevent damage to the side shield, the clips must be depressed in order to release the side shield from the cushion pan. 7. Unhook the side shield from the seat latch. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch - With Side Air Bag > Page 1143 8. Remove the side shield. 1 Disconnect the electrical connector. 2 Remove the side shield. 9. Remove the 6-way power seat switch. 1 Remove the screws. 2 Remove the 6-way power seat switch. INSTALLATION WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES AT THE BEGINNING OF THE REMOVAL PROCEDURE. 1. Install the 6-way power seat switch. 1 Install the 6-way power seat switch. 2 Install the screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch - With Side Air Bag > Page 1144 2. Install the side shield. 1 Install the side shield. 2 Install the electrical connector. 3. Hook the side shield to the seat latch. 4. Install the side shield clips. 5. Install the rear side shield screw. 6. Install the lumbar support knob. 7. Install the front seat. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE FRONT SEAT REMOVAL AND INSTALLATION PROCEDURE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch - With Side Air Bag > Page 1145 8. Reactivate the supplemental restraint system (SRS). WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. 9. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch - With Side Air Bag > Page 1146 Power Seat Switch: Service and Repair Seat Control Switch - Without Side Air Bag REMOVAL 1. Remove the front seat. 2. Remove the lumbar control knob, if equipped. 3. Disconnect the power seat switch electrical connector. 4. Remove the front seat cushion side shield rear screw. 5. Remove the front seat cushion side shield screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch - With Side Air Bag > Page 1147 6. Disconnect the front seat cushion side shield. CAUTION: Use care when disconnecting the seat cushion side shield from the seat cushion frame so the tabs on the seat cushion side shield are not damaged. 7. Remove the front seat cushion side shield. 8. Remove the 6-way power seat switch. - Remove the screws, then remove the 6-way power seat switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Page 1148 Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams Connector View C456 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams > Page 1152 Power Trunk / Liftgate Lock Switch: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams > Page 1153 Liftgate Door Lock Switch Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams Connector View C912 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 1157 Sunroof / Moonroof Switch: Service and Repair REMOVAL 1. Position the overhead console aside. 2. Remove the roof opening panel control switch. 1 Remove the screws. 2 Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 1162 Connector View C124 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Differential Speed Sensor > Component Information > Locations View 151-16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Differential Speed Sensor > Component Information > Locations > Page 1166 Connector View C455 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Specifications Parking Brake Release Switch: Specifications Parking brake remote release to instrument panel .................................................................................................................... 2.1-2.9 Nm (19-25 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Diagrams Connector View C2015 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications Front anti-lock brake sensor bolt ........................................................................................................................................................... (12 Nm) (8.5 ft. lbs.) Rear anti-lock brake sensor bolt ............................................................................................................................................................. (27 Nm) (20 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left front View 151-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left front > Page 1178 View 151-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front Connector View C150 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 1181 Connector View C160 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front Wheel Speed Sensor: Service and Repair Sensor, Front Sensor-Front Removal and Installation 1. Raise and support the vehicle. 2. Disconnect the front anti-lock brake sensor wire from the vehicle frame. 1 Disconnect the electrical connector. 2 Unclip the front anti-lock brake sensor wire from the vehicle frame. 3. Remove the front anti-lock brake sensor. 1 Remove the bolt. 2 Remove the front anti-lock brake sensor. 4. NOTE: Plug the sensor mount opening and thoroughly clean the mounting surface. Apply High-Temperature 4x4 Front Axle and Wheel Bearing Grease E8TZ-19590-A meeting Ford Specification ESA-MIC198-A. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front > Page 1184 Wheel Speed Sensor: Service and Repair Sensor, Rear Sensor-Rear Removal and Installation 1. Raise and support vehicle. NOTE: Clean off dirt and foreign material that may have collected around the rear anti-lock brake sensor before removal. 2. Remove the rear anti-lock brake sensor. 1 Disconnect the rear anti-lock brake sensor electrical connector. 2 Remove the bolt. 3 Remove the rear anti-lock brake sensor. 3. NOTE: Thoroughly clean the mounting surface. NOTE: Inspect the anti-lock brake sensor O-ring for damage; lightly lubricate the O-ring with SAE 75W-140 High Performance Rear Axle Lubricant FITZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations View 151-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Engine Coolant Temperature (ECT) Sender Connector View C1061 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Engine Coolant Temperature (ECT) Sender > Page 1192 Connector View C1064 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 1193 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Engine Coolant Temperature (ECT) Sensor The Engine Coolant Temperature (ECT) sensor (Figure 27) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. The ECT sensor is similar in construction to the IAT sensor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 1194 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector. 2. Remove the retaining clip and the ECT sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Description and Operation Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor Cylinder Head Temperature (CHT) Sensor The Cylinder Head Temperature (CHT) sensor (Figure 26) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The cylinder head temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. For additional information, refer to Powertrain Control Software for Fail-Safe Cooling Strategy details. See: Powertrain Management/Description and Operation/Powertrain Control Software Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications Temperature Sensor (Gauge): Specifications Engine coolant temperature (ECT) sensor ............................................................................................................................................ 10 Nm (89 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications > Page 1201 Temperature Sensor (Gauge): Service and Repair Sender Unit-Water Temperature Indicator Removal and Installation 1. Partially drain the cooling system. 2. Remove the thermostat. 3. Disconnect the electrical connector. 4. Remove the water temperature indicator sending unit. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1211 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1212 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1213 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1214 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1215 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1216 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1217 Attachment III - Technical Information Table of Contents Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1218 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1219 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1220 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1221 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1222 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1223 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1224 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1225 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1226 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1227 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1228 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1229 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1230 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1231 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1232 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1233 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1234 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1235 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1236 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): Recalls Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 1241 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1247 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1248 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1249 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1250 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1251 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1252 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1253 Attachment III - Technical Information Table of Contents Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1254 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1255 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1256 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1257 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1258 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1259 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1260 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1261 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1262 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1263 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1264 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1265 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1266 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1267 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1268 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1269 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1270 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1271 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1272 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): All Technical Service Bulletins Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 1277 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Deactivator Switch Connector View C1025 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Deactivator Switch > Page 1280 Connector View C278 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Technician Safety Information Brake Switch (Cruise Control): Technician Safety Information WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Technician Safety Information > Page 1283 Brake Switch (Cruise Control): Vehicle Damage Warnings CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Page 1284 Brake Switch (Cruise Control): Description and Operation Brake Pressure Applied Brake Deactivator Switch The Brake Pressure Applied (BPA) switch also sometimes called the brake deactivator switch for vehicle speed control deactivation. Is a normally closed switch, witch supplies battery positive voltage (B+) to the PCM when the brake pedal is NOT applied. When the brake pedal is depressed, the normally closed switch will open and power is removed from the PCM. On some applications the normally closed BPA switch along with the normally open brake pedal position (BPP) switch are used for a brake rationality test within the PCM. The PCM misfire monitor profile learn function can be disable if a brake switch failure occurs. If one or both brake pedal inputs to the PCM did not change states when they were expected to a diagnostic trouble code P1572 can be set by the PCM strategy. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Page 1285 Brake Switch (Cruise Control): Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the speed control deactivator switch electrical connector. 3. Remove the speed control deactivator switch. WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. INSTALLATION 1. To install, reverse the removal procedure. ^ Bleed the brake system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Diagrams Connector View C257 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair Cruise Control Switch: Service and Repair REMOVAL 1. Remove the steering wheel. 2. Remove the screws and the steering wheel rear cover. 3. Remove the ribbon harness from the clips. 4. Disconnect the horn contact electrical connectors. 5. Remove the screws and the right side horn contact. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Page 1292 6. Remove the screws and the speed control switch assembly. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams Connector View C103 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations View 151-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 1301 Connector View C132 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Description and Operation Blower Motor Switch: Description and Operation The blower motor switch controls blower motor speed by adding or by passing resistors in the heater blower motor switch resistor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Description and Operation Evaporator Temperature Sensor/Clutch Cycling Switch: Description and Operation Air Conditioning Evaporator Temperature Sensor A/C Evaporator Temperature (ACET) Sensor Voltage And Resistance Chart, Part 1 A/C Evaporator Temperature (ACET) Sensor Voltage And Resistance Chart, Part 2 The Air Conditioning Evaporative Temperature (ACET) sensor senses evaporator air discharge temperature. The ACET sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The PCM sources a low current 5 volts on the ACET circuit. With SIG RTN also connected to the ACET sensor, the varying resistance affects the voltage drop across the sensor terminals. As A/C evaporator air temperature changes, the varying resistance of the ACET sensor changes the voltage the PCM detects. The ACET sensor is used to more accurately control A/C clutch cycling, improving defrost/demist performance, reduce A/C clutch cycling, etc. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Diagrams Connector View C1078 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Left Connector View C458 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Left > Page 1317 Connector View C459 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Left > Page 1318 Door Switch: Diagrams Driver Side Front Connector View C526a Connector View C526b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Left > Page 1319 Door Switch: Diagrams Driver Side Rear Connector View C715a Connector View C715b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Left > Page 1320 Door Switch: Diagrams Connector View C458 Connector View C459 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Left > Page 1321 Connector View C526a Connector View C526b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Left > Page 1322 Connector View C715a Connector View C715b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Left > Page 1323 Connector View C602a Connector View C602b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Left > Page 1324 Connector View C820a Connector View C820b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Door Ajar Switch Door Switch: Service and Repair Door Ajar Switch REMOVAL 1. Remove the door interior trim panel. NOTE: Front door shown, rear door similar. 2. Position the watershield aside. 3. Disconnect the ground wire and remove the screw. 4. Remove the door ajar switch. - Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Door Ajar Switch > Page 1327 Door Switch: Service and Repair Door Ajar Switch - Liftgate REMOVAL 1. Remove the liftgate latch. 2. Remove the liftgate latch ajar switch. - Remove the screw. INSTALLATION 1. To install, reverse the removal process. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Diagrams Connector View C2015 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations View 151-16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 1335 Connector View C995 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations View 151-5 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Digital Transmission Range Sensor Connector View C167 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Digital Transmission Range Sensor > Page 1341 Connector View C169 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Diagrams Connector View C278 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Description and Operation > Brake Pedal Position Switch Brake Pedal Position Switch: Description and Operation Brake Pedal Position Switch Brake Pedal Position Switch Typical Brake Pedal Position Switch The Brake Pedal Position (BPP) switch (Figure 21) is used by the PCM to disengage the transmission torque converter clutch and on some applications as an input to the idle speed control for idle quality and for vehicle speed control deactivation. On most applications the BPP switch is hard wired to the PCM and supplies battery positive voltage (B+) when the vehicle brake pedal is applied. On other applications the BPP switch signal is broadcast over the SCP link via another module to be received by the PCM. On applications where the BPP switch is hard wired to the PCM and stoplamp circuit, if all stoplamp bulbs are burned out (open), high voltage is present at the PCM due to a pull-up resistor in the PCM. This provides fail-safe operation in the event the circuit to the stoplamp bulbs has failed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Description and Operation > Brake Pedal Position Switch > Page 1347 Brake Pedal Position Switch: Description and Operation Brake Pressure Applied Brake Deactivator Switch Brake Pressure Applied Brake Deactivator Switch The Brake Pressure Applied (BPA) switch also sometimes called the brake deactivator switch for vehicle speed control deactivation. Is a normally closed switch, witch supplies battery positive voltage (B+) to the PCM when the brake pedal is NOT applied. When the brake pedal is depressed, the normally closed switch will open and power is removed from the PCM. On some applications the normally closed BPA switch along with the normally open brake pedal position (BPP) switch are used for a brake rationality test within the PCM. The PCM misfire monitor profile learn function can be disable if a brake switch failure occurs. If one or both brake pedal inputs to the PCM did not change states when they were expected to a diagnostic trouble code P1572 can be set by the PCM strategy. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Description and Operation > Page 1348 Brake Pedal Position Switch: Service and Repair REMOVAL 1. Disconnect the Brake Pedal Position (BPP) switch electrical connector. 2. Remove the BPP switch. 1 Remove the self-locking pin. 2 Remove the spacer. 3 Remove the BPP switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Left Connector View C458 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Left > Page 1353 Connector View C459 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Left > Page 1354 Door Switch: Diagrams Driver Side Front Connector View C526a Connector View C526b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Left > Page 1355 Door Switch: Diagrams Driver Side Rear Connector View C715a Connector View C715b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Left > Page 1356 Door Switch: Diagrams Connector View C458 Connector View C459 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Left > Page 1357 Connector View C526a Connector View C526b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Left > Page 1358 Connector View C715a Connector View C715b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Left > Page 1359 Connector View C602a Connector View C602b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Left > Page 1360 Connector View C820a Connector View C820b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch Door Switch: Service and Repair Door Ajar Switch REMOVAL 1. Remove the door interior trim panel. NOTE: Front door shown, rear door similar. 2. Position the watershield aside. 3. Disconnect the ground wire and remove the screw. 4. Remove the door ajar switch. - Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch > Page 1363 Door Switch: Service and Repair Door Ajar Switch - Liftgate REMOVAL 1. Remove the liftgate latch. 2. Remove the liftgate latch ajar switch. - Remove the screw. INSTALLATION 1. To install, reverse the removal process. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams Connector View C240 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Page 1367 Fog/Driving Lamp Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the instrument panel finish panel. 1 Remove the screws. 2 Remove the center instrument panel finish panel. ^ Disconnect the electrical connectors. 3. Remove the fog lamp switch. 1 Remove the screws. 2 Remove the mounting bezel. 3 Release the two tabs and remove the fog lamp switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams Hazard Warning Switch: Diagrams Connector View C202a Connector View C202b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 1371 Hazard Warning Switch: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 1372 Multifunction Switch, Turn Portion Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 1373 Multifunction Switch, Turn Portion Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams Headlamp Dimmer Switch: Diagrams Connector View C202a Connector View C202b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 1377 Headlamp Dimmer Switch: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 1378 Multifunction Switch, Lamp Portion Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 1379 Multifunction Switch, Lamp Portion Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams Connector View C205 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 1383 Main Light Switch: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 1384 Main Light Switch, Exterior Lamps, Illumination Lamps Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 1385 Main Light Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the instrument panel center finish panel. 1 Remove the screws. 2 Remove the instrument panel center finish panel. ^ Disconnect electrical connectors. 3. Remove the hood latch release handle. 1 Remove the screws. 2 Remove the hood latch release handle. 4. Remove the lower instrument panel steering column cover. 1 Remove the screws. 2 Remove the lower instrument panel steering column cover. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 1386 5. Remove the bolts and the lower instrument panel reinforcement. 6. If equipped, position the column gear shift lever out of the way. 7. Position the cluster finish panel aside. 1 Remove the screws. 2 Position the cluster finish panel aside. 8. Remove the cluster finish pane 1 Disconnect the electrical connectors and remove the headlamp switch knob. 2 Remove the cluster finish panel. 9. Remove the headlamp switch. 1 Remove the screws. 2 Remove the headlamp switch. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 1387 INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service and Repair Horn Switch: Service and Repair REMOVAL 1. Remove the driver side air bag. 2. Remove the switch. 1 Disconnect the horn wire (BK) from the switches. 2 Remove the screws and the switch. INSTALLATION 3. To install, reverse the removal procedure. ^ Prove out the air bag system; refer to Air Bag Systems. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications Turn Signal Switch: Specifications Multi-Function Switch Screws ................................................................................................................................................. 2.1 2.9 Nm (19 - 25 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 1394 Turn Signal Switch: Diagrams Connector View C202a Connector View C202b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 1395 Turn Signal Switch: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 1396 Multifunction Switch, Turn Portion Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 1397 Multifunction Switch, Turn Portion Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 1398 Turn Signal Switch: Service and Repair Multifunction Switch Removal and Installation 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the upper and lower steering column shrouds. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 1399 5. Remove the multifunction switch. 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the multifunction switch. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Description and Operation Absolute Pressure Sensor: Description and Operation Thermal Manifold Absolute Pressure Sensor Thermal Manifold Absolute Pressure (TMAP) Sensor The Thermal Manifold Absolute Pressure Sensor (TMAP) (Figure 40) consists of a Manifold Absolute Pressure (MAP) sensor and an integrated thermistor. The thermistor part of the sensor is currently not being used. The MAP part of the sensor measures intake manifold air absolute pressure. The PCM uses information from the MAP sensor, Throttle Position (TP) sensor, mass air flow (MAF) sensor, engine coolant temperature (ECT) or cylinder head temperature (CHT) sensor and crankshaft position (CKP) sensor to determine how much exhaust gas is introduced into the intake manifold. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations View 151-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 1408 Connector View C128 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 1409 Mass Air Flow Sensor: Service Precautions CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 1410 Mass Air Flow Sensor: Description and Operation Mass Air Flow Sensor Typical Mass Air Flow (MAF) Sensor Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire Terminals The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 35). If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio (Figure 36). This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 1411 Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated intake air temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar, Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 1412 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Loosen the air cleaner outlet tube clamp and position the tube aside. 3. Remove the four bolts and the MAF sensor. CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations View 151-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1416 Connector View C180 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > PCM Input Camshaft Position Sensor: Description and Operation PCM Input Camshaft Position Sensor The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No.1 is on its compression stroke. A signal is then sent to the powertrain control module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctance Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22) and the two pin connector variable reluctance sensor (Figure 23). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > PCM Input > Page 1419 Camshaft Position Sensor: Description and Operation Ignition Systems Camshaft Position Sensor Camshaft Position (CMP) Sensor The camshaft position sensor (Figure 55) used by COP Integrated EI system is a magnetic transducer mounted on the engine front cover adjacent to the camshaft. By monitoring a target on the camshaft sprocket, the CMP sensor identifies cylinder one to the PCM. The COP Integrated EI system uses this information to synchronize the firing of the individual coils. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 1420 Camshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams Connector View C257 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams > Page 1424 Clutch Switch: Description and Operation Clutch Pedal Position Switch Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch (Figure 24) is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations View 151-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Engine Coolant Temperature (ECT) Sender Connector View C1061 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Engine Coolant Temperature (ECT) Sender > Page 1430 Connector View C1064 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 1431 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Engine Coolant Temperature (ECT) Sensor The Engine Coolant Temperature (ECT) sensor (Figure 27) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. The ECT sensor is similar in construction to the IAT sensor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 1432 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector. 2. Remove the retaining clip and the ECT sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations View 151-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1436 Connector View C101 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > PCM Input Crankshaft Position Sensor: Description and Operation PCM Input Crankshaft Position Sensor (Integrated Ignition Systems) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the powertrain control module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to fixed reference (Figure 25). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > PCM Input > Page 1439 Crankshaft Position Sensor: Description and Operation Ignition Systems Crankshaft Position Sensor Typical Crankshaft Position (CKP) Sensor The crankshaft position (CKP) sensor (Figure 54) is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP sensor is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to a fixed reference (Figure 54) for the CKP sensor configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between teeth. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Page 1440 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Crankshaft Position (CKP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ The new CKP sensor needs to be touching the damper. The new sensor has wear tabs that will wear off after several engine revolutions. ^ Be sure the sensor wiring is routed away from the battery cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor Cylinder Head Temperature (CHT) Sensor The Cylinder Head Temperature (CHT) sensor (Figure 26) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The cylinder head temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. For additional information, refer to Powertrain Control Software for Fail-Safe Cooling Strategy details. See: Powertrain Management/Description and Operation/Powertrain Control Software Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions Fuel Tank Pressure Sensor: Service Precautions CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions > Page 1447 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure Sensor Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The Fuel Tank Pressure (FTP) sensor (Figure 97) or inline fuel tank pressure (FTP) sensor (Figure 98) is used to measure the fuel tank pressure during the EVAP monitor test on vehicles equipped with the Running Loss-type system. Also, it is used to control excessive fuel tank pressure by forcing the system to purge. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions > Page 1448 Fuel Tank Pressure Sensor: Service and Repair REMOVAL 1. Remove the fuel tank. 2. Remove the fuel tank pressure sensor. 1 Disconnect the electrical connector. 2 Press down and rotate the fuel tank pressure sensor counterclockwise and remove it from the fuel tank. CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. INSTALLATION 1. To install, reverse removal procedure. ^ Leak test. See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Evaporative Emission System Leak Test ^ Carry out the evaporative emissions repair verification drive cycle. See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Evaporative Emission Repair Verification Drive Cycle Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Description and Operation Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor Intake Air Temperature (IAT) The Intake Air Temperature (IAT) sensors (Figure 33) and integrated Mass Air Flow (MAF) type (Figure 36), are thermistor devices in which resistance changes with temperature The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of fuel, spark and MAF. The IAT sensor provides a quicker temperature change response time than the ECT or CHT sensor. Supercharged vehicles use (2) IAT sensors. Both sensors are thermistor type devices and operate as above. However, one is located before the supercharger at the air cleaner for standard OBD II/cold weather input, while a second sensor (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control border-line spark and to help determine intercooler efficiency. Currently two types of IAT2 sensors are used. A screw in type (Figure 33) and an integrated type, witch is part of the Thermal Manifold Absolute Pressure (TMAP) sensor (Figure 40). The TMAP sensor consists of a IAT thermistor and a Manifold Absolute Pressure (MAP) sensor. The thermistor portion of the TMAP is used for IAT2 function and operates in the same manner as a non-integrated IAT2. For additional information on the MAP portion of the TMAP, refer to the Thermal Manifold Absolute Pressure Sensor description and operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations View 151-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 1455 Connector View C109 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 1456 Knock Sensor: Description and Operation Knock Sensor Knock Sensor (KS) The knock Sensor (KS) (Figure 34) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 1457 Knock Sensor: Service and Repair REMOVAL 1. Disconnect the Knock Sensor (KS) electrical connector. 2. Remove the intake manifold. 3. Remove the KS. 1 Remove the bolt. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Description and Operation Oil Temperature Sensor For ECM: Description and Operation Engine Oil Temperature Engine Oil Temperature (EOT) Sensor The Engine Oil Temperature (EOT) sensor (Figure 29) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The EOT measures the temperature of the engine oil. The EOT sensor is similar in construction to the engine coolant temperature (ECT) sensor. On some applications, EOT input to the PCM is used to initiate a soft engine shutdown. This prevents engine damage from occurring as a result of high oil temperature. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions Heated Oxygen Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. NOTE: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1466 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number or the component name in one of the the A-Z Component Lists, the Component Location description for that component can easily be found. See: Locations/Component Locations/A-Z Component List Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1467 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1468 the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1469 that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1470 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1471 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1472 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1473 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1474 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1475 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1476 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1477 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1478 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1479 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1480 Systems Overview Wire Color Code Identification Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1481 OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1482 Heated Oxygen Sensor: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1483 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1484 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1485 Heated Oxygen Sensor: Connector Views Connector View C171 Connector View C142 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1486 Connector View C172 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 1487 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > PCM Input Heated Oxygen Sensor: Description and Operation PCM Input Heated Oxygen Sensor Heated Oxygen Sensor (HO2S) The Heated Oxygen Sensor (HO2S) (Figure 32) detects the presence of oxygen in the exhaust and produces a variable voltage according to the amount of oxygen detected. A high concentration of oxygen (lean air/fuel ratio) in the exhaust produces a low voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a high voltage signal greater than 0.6 volt. The HO2S provides feedback to the PCM indicating air/fuel ratio in order to achieve a near stoichiometric air/fuel ratio of 14.7:1 during closed loop engine operation. The HO2S generates a voltage between 0.0 and 1.1 volts. Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to temperatures of 800°C (1400°F). At approximately 300°C (600°F) the engine can enter closed loop operation. The VPWR circuit supplies voltage to the heater and the PCM will complete the ground when the proper conditions occur. For model year 1998 a new HO2S heater and heater control system are installed on some vehicles. The high power heater reaches closed loop fuel control temperatures. The use of this heater requires that the HO2S heater control be duty cycled, to prevent damage to the heater. The 6 ohm design is not interchangeable with new style 3.3 ohm heater. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > PCM Input > Page 1490 Heated Oxygen Sensor: Description and Operation Upstream Heated and Downstream Heated Oxygen Sensors Upstream Heated and Downstream Heated Oxygen Sensors The HO2S provide the Powertrain Control Module (PCM) with voltage and frequency information related to the oxygen content of the exhaust gas. (Refer to the PCM Inputs for a description of how the HO2S operates.) In addition to providing the PCM with indications of how rich/lean the engine is operating, the upstream HO2S signal serves as an input to the HO2S monitor. The downstream HO2S signal is an input to the Catalyst Efficiency monitor. (Refer to the OBD II Monitors for specific information on these monitors.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Page 1491 Heated Oxygen Sensor: Service and Repair Socket, Exhaust Gas Oxygen Sensor SPECIAL TOOL(S) REMOVAL Left side sensor 1. Raise and support the vehicle. Right side sensor 2. Remove the right front wheel and tire assembly. 3. Position aside the right front fender splash shield. Both sensors 4. Using the special tool, remove the HO2S. NOTE: If necessary, lubricate the HO2S with lock lubricant to assist in removal. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Apply a light coat of anti-seize lubricant to the threads of the HO2S. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Page 1492 Socket, Exhaust Gas Oxygen Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1501 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1502 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1503 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1504 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1505 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1511 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1512 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1513 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1514 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1515 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1520 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1521 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1522 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1528 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1529 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1530 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 1531 View 151-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 1532 Connector View C1068 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 1533 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR Sensor Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 86) is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Tube Mounted Differential Pressure Feedback EGR Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 1534 Tube Mounted Differential Pressure Feedback EGR Sensor The tube mounted differential pressure feedback EGR sensor (Figure 87) is identical in operation as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the underside of the sensor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 1535 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the differential pressure feedback Exhaust Gas Recirculation (EGR). 1 Disconnect the electrical connector. 2 Disconnect the hoses. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations View 151-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 1539 Connector View C189 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 1540 Throttle Position Sensor: Description and Operation Throttle Position Sensor Typical Throttle Position (TP) Sensor The throttle position (TP) sensor (Figure 41) is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is monitored by the OBD II system for component integrity, system functionality, and faults that can cause emissions levels to exceed standards set in government regulations. For additional information on the TP sensor, refer to Electronic EC System Hardware-PCM Inputs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 1541 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove the accelerator control snow shield. 2. Remove the Throttle Position (TP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolts and the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission Range (TR) sensor screws .......................................................................................................................... 8-11 Nm (71-97 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 1545 View 151-5 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 1546 Connector View C167 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 1547 Digital Transmission Range Sensor: Description and Operation Digital Transmission Range (TR) Sensor The digital Transmission Range (TR) sensor is located on the outside of the transmission at the manual lever. The digital TR sensor completes the start circuit in PARK, NEUTRAL, and the back-up lamp circuit in REVERSE. The digital TR sensor also opens and closes a set of four switches that are monitored by the Powertrain Control Module (PCM) to determine the position of the manual lever (P, R, N, (D), 3, 2, 1). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 1548 Digital Transmission Range Sensor: Service and Repair Digital Transmission Range (TR) Sensor Special Tools Special Tool(s) Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Disconnect the shift cable from the manual control lever. 4. Disconnect the digital Transmission Range (TR) sensor electrical connector. 5. Remove the manual control outer lever nut and manual control outer lever. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 1549 6. Remove the screws and the digital TR sensor. Installation 1. Install the digital TR sensor and loosely install the screws. 2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence. 3. Install the manual control outer lever and nut. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 1550 4. Connect the digital Transmission Range (TR) sensor electrical connector. 5. Connect the shift cable to the manual control lever. 6. Verify that the shift cable is adjusted. 7. Lower the vehicle. 8. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > PCM Input Vehicle Speed Sensor: Description and Operation PCM Input Vehicle Speed Sensor Typical Vehicle Speed Sensor (VSS) The Vehicle Speed Sensor (VSS) (Figure 44) is a variable reluctance or Hall-effect sensor that generates a waveform with a frequency that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the VSS (and other inputs) to control such parameters as fuel injection, ignition control, transmission/transaxle shift scheduling and torque converter clutch scheduling. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > PCM Input > Page 1555 Vehicle Speed Sensor: Description and Operation PCM Output Powertrain Control Module - Vehicle Speed Output (VSO) The PCM-VSO (Powertrain Control Module - Vehicle Speed Output) speed signal subsystem generates vehicle speed information for distribution to the vehicle's electrical/electronic modules and subsystems that require vehicle speed data. This subsystem senses the transmission output shaft speed with a sensor. The data is processed by the PCM, and distributed as a hard-wired signal or as a multiplexed data message. The key features of the PCM-VSO system are to: ^ Infer vehicle movement from the output shaft sensor signal ^ Convert transmission output shaft rotational information to vehicle speed information ^ Compensate for tire size and axle ratio with a programmed calibration variable ^ Utilize a transfer case sensor for four wheel drive applications ^ Distribute vehicle speed information as a multiplexed message and/or an analog signal The signal from a non-contact shaft sensor (Output Shaft Sensor--OSS or Transfer Case Shaft Sensor--TCSS) mounted on the transmission (automatics, manuals, or 4X4 transfer cases) is sensed directly by the PCM. The PCM converts the OSS or TCSS information to 8000 pulses per mile, based on a tire and axle ratio conversion factor. This conversion factor is programmed into the PCM at the time the vehicle is assembled and can be reprogrammed in the field for servicing changes in the tire size and axle ratio. The PCM transmits the computed vehicle speed and distance traveled information to all the vehicle speed signal users on the vehicle. VSO information can be transmitted by a hard-wired interface between the vehicle speed signal user and the PCM, or by Speed and Odometer SCP multiplexed data messages. The VSO hard-wired signal wave form is a DC square wave with a voltage level of 0 to VBAT. Typical output operating range is 2.22Hz per MPH ( 1.3808 Hz pr 1 Km/h). Multiplexed data for speed and distance data are transmitted as separate SCP messages over the SCP multiplex link. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1565 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1566 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1567 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1568 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1569 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1575 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1576 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1577 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1578 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1579 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1584 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1585 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1586 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 1592 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 1593 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 1594 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 1595 View 151-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 1596 Connector View C1068 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 1597 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR Sensor Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 86) is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Tube Mounted Differential Pressure Feedback EGR Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 1598 Tube Mounted Differential Pressure Feedback EGR Sensor The tube mounted differential pressure feedback EGR sensor (Figure 87) is identical in operation as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the underside of the sensor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 1599 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the differential pressure feedback Exhaust Gas Recirculation (EGR). 1 Disconnect the electrical connector. 2 Disconnect the hoses. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations View 151-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 1604 Connector View C128 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 1605 Mass Air Flow Sensor: Service Precautions CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 1606 Mass Air Flow Sensor: Description and Operation Mass Air Flow Sensor Typical Mass Air Flow (MAF) Sensor Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire Terminals The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 35). If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio (Figure 36). This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 1607 Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated intake air temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar, Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 1608 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Loosen the air cleaner outlet tube clamp and position the tube aside. 3. Remove the four bolts and the MAF sensor. CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations View 151-15 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 1612 Connector View C435 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 1613 Fuel Pressure Sensor/Switch: Description and Operation Fuel Rail Pressure Sensor Fuel Rail Pressure (FRP) Sensor The Fuel Rail Pressure (FRP) sensor (Figure 30) is a diaphragm strain gauge device in which resistance changes with pressure. The electrical resistance of a strain gauge increases as pressure increases, and decreases as pressure decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to pressure. Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. Fuel Rail Pressure (FRP) Sensor The fuel rail pressure (FRP) sensor (Figure 31) senses the pressure difference between the fuel rail and the intake manifold. The return fuel line to the fuel tank has been deleted in this type of fuel system. The differential fuel/intake manifold pressure together with measured fuel temperature provides an indication of the fuel vapors in the fuel rail. Both differential pressure and temperature feedback signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserve fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and Operation Fuel Temperature Sensor: Description and Operation Engine Fuel Temperature Sensor Engine Fuel Temperature (EFT) Sensor The Engine Fuel Temperature (EFT) sensor (Figure 28) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The EFT sensor measures the temperature of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations View 151-11 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 1620 Connector View C282 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 1621 Inertia Fuel Shutoff Switch: Description and Operation Inertia Fuel Shutoff (IFS) Switch The Inertia Fuel Shutoff (IFS) switch (Figure 72) is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shut off the fuel pump if a collision occurs. It consists of a steel ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and shuts off the electric fuel pump. Once the switch is open, it must be manually reset before restarting the vehicle. Refer to the Owner Guide for the location of the IFS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 1622 Inertia Fuel Shutoff Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Access the Inertia Fuel Shutoff (IFS) switch on the RH A-pillar lower trim panel and disconnect the electrical connector. 3. Remove the bolts and remove the IFS switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations View 151-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 1626 Connector View C189 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 1627 Throttle Position Sensor: Description and Operation Throttle Position Sensor Typical Throttle Position (TP) Sensor The throttle position (TP) sensor (Figure 41) is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is monitored by the OBD II system for component integrity, system functionality, and faults that can cause emissions levels to exceed standards set in government regulations. For additional information on the TP sensor, refer to Electronic EC System Hardware-PCM Inputs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 1628 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove the accelerator control snow shield. 2. Remove the Throttle Position (TP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolts and the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations View 151-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1633 Connector View C180 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > PCM Input Camshaft Position Sensor: Description and Operation PCM Input Camshaft Position Sensor The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No.1 is on its compression stroke. A signal is then sent to the powertrain control module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctance Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22) and the two pin connector variable reluctance sensor (Figure 23). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > PCM Input > Page 1636 Camshaft Position Sensor: Description and Operation Ignition Systems Camshaft Position Sensor Camshaft Position (CMP) Sensor The camshaft position sensor (Figure 55) used by COP Integrated EI system is a magnetic transducer mounted on the engine front cover adjacent to the camshaft. By monitoring a target on the camshaft sprocket, the CMP sensor identifies cylinder one to the PCM. The COP Integrated EI system uses this information to synchronize the firing of the individual coils. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 1637 Camshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations View 151-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1641 Connector View C101 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > PCM Input Crankshaft Position Sensor: Description and Operation PCM Input Crankshaft Position Sensor (Integrated Ignition Systems) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the powertrain control module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to fixed reference (Figure 25). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > PCM Input > Page 1644 Crankshaft Position Sensor: Description and Operation Ignition Systems Crankshaft Position Sensor Typical Crankshaft Position (CKP) Sensor The crankshaft position (CKP) sensor (Figure 54) is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP sensor is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to a fixed reference (Figure 54) for the CKP sensor configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between teeth. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Page 1645 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Crankshaft Position (CKP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ The new CKP sensor needs to be touching the damper. The new sensor has wear tabs that will wear off after several engine revolutions. ^ Be sure the sensor wiring is routed away from the battery cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Specifications Ignition Switch Lock Cylinder: Specifications Lock Cylinder Housing Screws ............................................................................................................ .................................................... 22 Nm (16 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder-Functional Lock Cylinder Removal 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock cylinder. 3. To install, reverse the removal procedure. ^ Verify ignition switch lock cylinder operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 1652 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional Ignition Switch Lock Cylinder-Non-Functional Lock Cylinder Removal and Installation 1. NOTE: Make sure the front wheels are in the straight-ahead position. Disconnect the battery ground cable and wait at least one minute. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes and instructions in the steering wheel removal and installation procedure. Remove the steering wheel assembly. 3. Twist off the cap from the ignition switch cylinder. 4. NOTE: The lock cylinder is repaired by discarding the inoperative lock cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code oil the vehicle. Remove the ignition switch lock cylinder. ^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. ^ Use a 3/8-inch drill bit to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. ^ Remove and discard the ignition switch lock cylinder and clean the drill shavings from the steering column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 1653 5. Remove the bearing retainer. 6. Remove the bearing and gear. ^ Thoroughly clean all drill shavings from the steering column and inspect it for damage. 7. To install, reverse the removal procedure. ^ Install a new ignition switch lock cylinder. ^ Verify ignition switch lock cylinder operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations View 151-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 1657 Connector View C109 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 1658 Knock Sensor: Description and Operation Knock Sensor Knock Sensor (KS) The knock Sensor (KS) (Figure 34) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 1659 Knock Sensor: Service and Repair REMOVAL 1. Disconnect the Knock Sensor (KS) electrical connector. 2. Remove the intake manifold. 3. Remove the KS. 1 Remove the bolt. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications Torque Specifications Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Right Connector View C304 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Right > Page 1666 Connector View C305 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service Precautions > Customer Safety Information Impact Sensor: Customer Safety Information WARNING: MOUNTING ORIENTATION OF THE IMPACT SENSORS AND THE RCM IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE RCM MOUNTING AREA FOR DEFORMATION. INSPECT THE IMPACT SENSOR MOUNTING AREA FOR DAMAGE. IF DAMAGED, THE RCM AND SENSORS MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE MOUNTING AREA OF THE RCM AND IMPACT SENSORS ARE RESTORED TO THE ORIGINAL PRODUCTION CONFIGURATION. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service Precautions > Customer Safety Information > Page 1669 Impact Sensor: Technician Safety Information WARNING: ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, CAUTIONS AND NOTES AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE AND AT THE BEGINNING OF THE REMOVAL PROCEDURE. Refer to Air Bag(s) Arming and Disarming. ^ THE TIGHTENING TORQUE OF THE AIR BAG SIDE IMPACT SENSOR RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service Precautions > Page 1670 Impact Sensor: Description and Operation WARNING: MOUNTING ORIENTATION OF THE IMPACT SENSORS AND THE RCM IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE RCM MOUNTING AREA FOR DEFORMATION. INSPECT THE IMPACT SENSOR MOUNTING AREA FOR DAMAGE. IF DAMAGED, THE RCM AND SENSORS MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE MOUNTING AREA OF THE RCM AND IMPACT SENSORS ARE RESTORED TO THE ORIGINAL PRODUCTION CONFIGURATION. The impact sensors provide data to the RCM for use in calculating impact severity. This is accomplished using various electrical and electro-mechanical sensors located throughout the vehicle. Side impact sensors are located on the LH and RH B-pillars. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation Impact Sensor: Service and Repair Removal and Installation Side Impact Sensor - Driver Side Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Deactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. Refer to Air Bag(s) Arming and Disarming. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1673 3. Remove the LH rear quarter trim panel. 4. Disengage the wire harness pin-type retainers from the B-pillar and position the wire harness out of the way. 5. Position the side impact sensor with the bracket away from the B-pillar. 1 Remove the bolts. 2 Position the side impact sensor with the bracket away from the B-pillar. 6. Remove the side impact sensor. 1 Disconnect the electrical connector. 2 Remove the side impact sensor. INSTALLATION WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, CAUTIONS AND NOTES AT THE BEGINNING OF THE REMOVAL PROCEDURE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1674 1. Connect the side impact sensor electrical connector. 1 Position the side impact sensor. 2 Connect the side impact sensor electrical connector. 2. Install the side impact sensor. 1 Position the side impact sensor with the bracket to the B-pillar. 2 Install the bolts. WARNING: THE TIGHTENING TORQUE OF THE AIR BAG SIDE IMPACT SENSOR RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 3. Connect the battery ground cable. 4. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 5. Disconnect the battery ground cable and wait at least one minute. 6. Route the wire harness and attach the pin-type retainers to the B-pillar. 7. Install the LH rear quarter trim panel. 8. Reactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. Refer to Air Bag(s) Arming and Disarming. 9. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1675 VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 10. Check the active restraint system for correct operation. Side Impact Sensor - Passenger Side Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Deactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. Refer to Air Bag(s) Arming and Disarming. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1676 3. Remove the RH rear quarter trim panel. 4. Disengage the wire harness pin-type retainers from the B-pillar and position the wire harness out of the way. 5. Position the side impact sensor with the bracket away from the B-pillar. 1 Remove the bolts. 2 Position the side impact sensor with the bracket away from the B-pillar. 6. Remove the side impact sensor. 1 Disconnect the electrical connector. 2 Remove the side impact sensor. INSTALLATION WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, CAUTIONS AND NOTES AT THE BEGINNING OF THE REMOVAL PROCEDURE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1677 1. Connect the side impact sensor electrical connector. 1 Position the side impact sensor. 2 Connect the side impact sensor electrical connector. 2. Install the side impact sensor. 1 Position the side impact sensor with the bracket to the B-pillar. 2 Install the bolts. WARNING: THE TIGHTENING TORQUE OF THE AIR BAG SIDE IMPACT SENSOR RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 3. Connect the battery ground cable. 4. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 5. Disconnect the battery ground cable and wait at least one minute. 6. Route the wire harness and attach the pin-type retainers to the B-pillar. 7. Install the RH rear quarter trim panel. 8. Reactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. Refer to Air Bag(s) Arming and Disarming. 9. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1678 VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 10. Check the active restraint system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1679 Impact Sensor: Service and Repair General Procedures "J" Nut, Restraints Control Module (RCM) and Side Impact Sensor WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both this procedures and Weld Nut Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Impact Sensor before proceeding with the repair. ^ If two or more weld nuts are missing, do not install the "J" nuts as outlined in this procedure. Weld nuts must be installed as outlined in Weld Nut Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Impact Sensor. ^ The following procedure applies to vehicles that have a rectangular hole in the sheet metal that is in close proximity to the missing weld nut. 1. Obtain a "J" nut (part number N623332-S301) or any of the following optional "J" nuts (part numbers: N623342-S101, N800854-S100, N800925-S100). 2. Obtain a 6 mm (0.24 in) grounding screw or equivalent. 3. Install the "J,' nut through the rectangular hole in the sheet metal. 4. Install the crash sensor. NOTE: Be sure the threaded portion of the "J" nut is aligned with the clearance hole in the sheet metal. 5. Tighten the attaching screws to specification. Refer to Torque Specifications. Missing Weld Nut, RCM and Side Impact Sensor WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both this procedure and Weld Nut Repair - "J" Nut, Restraints Control Module (RCM) and Side Impact Sensor before proceeding with the repair. ^ Use only this procedure if two or more weld nuts are missing, do not install the "J" nuts as outlined in Weld Nut Repair - "J" Nut, Restraints Control Module (RCM) and Side Crash Sensor. ^ Radiator support repair shown, others are similar. 1. Obtain a 6 mm (0.24 in) weld nut. 2. Obtain a 6 mm (0.24 in) grounding screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 1680 3. Route a sufficient length of copper welding wire through the weld nut clearance hole and back out an adjacent access hole. 4. Feed the copper welding wire through the weld nut, then through a standard flat washer. 5. Secure the flat washer so that it cannot he pulled off the end of the copper welding wire. 6. Pull the copper welding wire back through the clearance hole, allowing the weld nut and flat washer to follow the copper welding wire through. 7. Position the weld nut to the weld nut clearance hole, firmly pulling on the copper welding wire allowing the secured flat washer to hold the weld nut in position. 8. Holding the weld nut securely in place and using a MIG welder, weld in four places around the edge of the weld nut. 9. Metal finish as required. 10. Verify the nut is securely in place. 11. In stall the crash sensor. 12. Tighten the attaching screws to specification. Refer to Torque Specifications. Stripped Weld Nut, RCM and Side Impact Sensor WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 1. Obtain an 8 mm (0.32 in) grounding screw. 2. Drill out the internal threads of the stripped-out weld nut to 7.37 mm (0.29 in) using a letter "L" size drill bit. 3. Position the crash sensor to the vehicle. 4. Install the 8 mm (0.32 in) grounding screw into the drilled-out weld nut. 5. Install the remaining attaching screws. 6. Tighten the attaching screws to specification. Refer to Torque Specifications. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Page 1681 Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Safing Sensor, Air Bag > Component Information > Description and Operation Safing Sensor: Description and Operation The safety sensor is internal to the RCM and is not serviced separately. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams Connector View C323 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Diagrams Connector View C257 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Specifications Ignition Switch Lock Cylinder: Specifications Lock Cylinder Housing Screws ............................................................................................................ .................................................... 22 Nm (16 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder-Functional Lock Cylinder Removal 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock cylinder. 3. To install, reverse the removal procedure. ^ Verify ignition switch lock cylinder operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 1698 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional Ignition Switch Lock Cylinder-Non-Functional Lock Cylinder Removal and Installation 1. NOTE: Make sure the front wheels are in the straight-ahead position. Disconnect the battery ground cable and wait at least one minute. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes and instructions in the steering wheel removal and installation procedure. Remove the steering wheel assembly. 3. Twist off the cap from the ignition switch cylinder. 4. NOTE: The lock cylinder is repaired by discarding the inoperative lock cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code oil the vehicle. Remove the ignition switch lock cylinder. ^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. ^ Use a 3/8-inch drill bit to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. ^ Remove and discard the ignition switch lock cylinder and clean the drill shavings from the steering column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 1699 5. Remove the bearing retainer. 6. Remove the bearing and gear. ^ Thoroughly clean all drill shavings from the steering column and inspect it for damage. 7. To install, reverse the removal procedure. ^ Install a new ignition switch lock cylinder. ^ Verify ignition switch lock cylinder operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Digital Transmission Range Sensor <--> [Neutral Safety Switch] > Component Information > Locations View 151-5 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Digital Transmission Range Sensor <--> [Neutral Safety Switch] > Component Information > Locations > Page 1703 Connector View C167 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Digital Transmission Range Sensor <--> [Neutral Safety Switch] > Component Information > Locations > Page 1704 Digital Transmission Range Sensor: Description and Operation Digital Transmission Range (TR) Sensor The digital Transmission Range (TR) sensor is located on the outside of the transmission at the manual lever. The digital TR sensor completes the start circuit in PARK, NEUTRAL, and the back-up lamp circuit in REVERSE. The digital TR sensor also opens and closes a set of four switches that are monitored by the Powertrain Control Module (PCM) to determine the position of the manual lever (P, R, N, (D), 3, 2, 1). See: Sensors and Switches - Powertrain Management/Sensors and Switches - Computers and Control Systems/Digital Transmission Range Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Specifications Steering Angle Sensor: Specifications Steering Wheel Rotation Sensor Bolts .................................................................................................................................................... 1 Nm (10 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Specifications > Page 1710 Steering Angle Sensor: Service and Repair "For information regarding this component please refer to steering column service and repair" Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Specifications Steering Angle Sensor: Specifications Steering Wheel Rotation Sensor Bolts .................................................................................................................................................... 1 Nm (10 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Specifications > Page 1715 Steering Angle Sensor: Service and Repair "For information regarding this component please refer to steering column service and repair" Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams Connector View C167 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams Connector View C279 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > PCM Inputs Transmission Mode Switch: Description and Operation PCM Inputs TRANSMISSION CONTROL SWITCH Transmission Control Switch (TCS) Transmission Control Switch (TCS) The Transmission Control Switch (TCS) (Figures 43 and 44) signals the PCM with key power whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > PCM Inputs > Page 1726 Transmission Mode Switch: Description and Operation PCM Output Transmission Control Indicator Lamp The Transmission Control Indicator Lamp (TCIL) is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Refer to Transmission Control Switch in Hardware PCM Inputs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > Page 1727 Transmission Mode Switch: Service and Repair Transmission Control Switch Removal and Installation 1. Remove the Transmission Control Switch (TCS). 1 Remove the cover. 2 Remove the TCS. 2. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission Range (TR) sensor screws .......................................................................................................................... 8-11 Nm (71-97 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 1731 View 151-5 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 1732 Connector View C167 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 1733 Digital Transmission Range Sensor: Description and Operation Digital Transmission Range (TR) Sensor The digital Transmission Range (TR) sensor is located on the outside of the transmission at the manual lever. The digital TR sensor completes the start circuit in PARK, NEUTRAL, and the back-up lamp circuit in REVERSE. The digital TR sensor also opens and closes a set of four switches that are monitored by the Powertrain Control Module (PCM) to determine the position of the manual lever (P, R, N, (D), 3, 2, 1). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 1734 Digital Transmission Range Sensor: Service and Repair Digital Transmission Range (TR) Sensor Special Tools Special Tool(s) Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Disconnect the shift cable from the manual control lever. 4. Disconnect the digital Transmission Range (TR) sensor electrical connector. 5. Remove the manual control outer lever nut and manual control outer lever. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 1735 6. Remove the screws and the digital TR sensor. Installation 1. Install the digital TR sensor and loosely install the screws. 2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence. 3. Install the manual control outer lever and nut. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 1736 4. Connect the digital Transmission Range (TR) sensor electrical connector. 5. Connect the shift cable to the manual control lever. 6. Verify that the shift cable is adjusted. 7. Lower the vehicle. 8. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Turbine shaft speed (TSS) sensor screw ....................................................................................................................................... 8-11 Nm (71-97 inch lbs.) Output shaft speed sensor (OSS) sensor screw ............................................................................................................................. 8-11 Nm (71-97 inch lbs.) Intermediate shaft speed sensor (ISS) sensor ................................................................................................................................ 8-11 Nm (71-97 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor View 151-5 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 1742 Transmission Speed Sensor: Locations Output Shaft Speed Sensor View 151-5 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 1743 View 151-6 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Intermediate Shaft Speed Sensor Connector View C164 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Intermediate Shaft Speed Sensor > Page 1746 Transmission Speed Sensor: Diagrams Output Shaft Speed Sensor Connector View C193 Connector View C1107 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 1747 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED SENSOR The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Removal 1. Raise and support the vehicle. 2. Disconnect Output Shaft Speed (OSS) sensor electrical connector. 3. Remove OSS sensor. 1 Remove the OSS sensor screw. 2 Remove the OSS sensor from the transmission. - Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring. Installation 1. Inspect and lubricate O-ring with petroleum jelly. 1 Install the OSS sensor into the transmission. 2 Tighten OSS sensor screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor > Page 1750 2. Connect OSS sensor electrical connector. 3. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor > Page 1751 Transmission Speed Sensor: Service and Repair Intermediate Shaft Speed Sensor Intermediate Shaft Speed Sensor Removal 1. Raise and support the vehicle. 2. Disconnect Intermediate Shaft Speed (ISS) sensor electrical connector. 3. Remove ISS sensor. 1 Remove the ISS sensor screw. 2 Remove the ISS sensor from the transmission. - Inspect the ISS sensor O-ring for damage. If damaged, install a new O-ring. Installation 1. Inspect and lubricate O-ring with petroleum jelly. 1 Install the ISS sensor into the transmission. 2 Tighten ISS sensor screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor > Page 1752 2. Connect ISS sensor electrical connector. 3. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations The Transmission Fluid Temperature Sensor is located on the solenoid body. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Temperature Sensor/Switch: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. NOTE: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1758 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number or the component name in one of the the A-Z Component Lists, the Component Location description for that component can easily be found. See: Locations/Component Locations/A-Z Component List Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1759 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1760 the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1761 that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1762 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1763 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1764 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1765 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1766 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1767 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1768 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1769 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1770 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1771 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1772 Systems Overview Wire Color Code Identification Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1773 OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1774 Transmission Temperature Sensor/Switch: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1775 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1776 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1777 Transmission Temperature Sensor/Switch: Electrical Diagrams Diagram 29-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1778 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Page 1779 Transmission Temperature Sensor/Switch: Description and Operation Transmission Fluid Temperature (TFT) Sensor The transmission fluid temperature (TFT) sensor is a thermistor-type sensor that varies a reference voltage signal. The resistance in the TFT varies with temperature. The powertrain control module (PCM) monitors the voltage signal across the TFT, and uses this information to determine the transmission fluid temperature. The TFT is located on the main control body wiring harness assembly. The PCM uses the TFT signal to help determine shift scheduling, torque converter clutch operation and electronic pressure control (EPC). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications Transmission Speed Sensor: Specifications Vehicle speed sensor bolt ......................................................................................................................................................... 11-13 Nm (98-115 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Diagrams Connector View C241 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Rear Window Adjust Switch Connector View C2060 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Rear Window Adjust Switch > Page 1792 Power Window Switch: Diagrams Master Window Adjust Switch Connector View C504a Connector View C504b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Rear Window Adjust Switch > Page 1793 Connector View C701 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Rear Window Adjust Switch > Page 1794 Connector View C604 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Rear Window Adjust Switch > Page 1795 Connector View C801 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch Power Window Switch: Testing and Inspection Master Window Adjust Switch Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 1798 Master Window Adjust Switch Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 1799 Master Window Adjust Switch Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 1800 Power Window Switch: Testing and Inspection Power window Switch Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 1801 Power Window Switch, Passenger Door Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 1802 Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 1803 Power Window Switch, LH Side Rear Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 1804 Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 1805 Power Window Switch, RH Side Rear Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Page 1806 Power Window Switch: Service and Repair REMOVAL NOTE: Driver window control switch shown, all others are similar. Front door 1. Disconnect the battery ground cable. All doors 2. Remove the window control switch panel. ^ Disconnect the electrical connectors. 3. Remove the window control switch. ^ Release the locking clips. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams Windshield Washer Switch: Diagrams Connector View C202a Connector View C202b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 1811 Windshield Washer Switch: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 1812 Multifunction Switch, Wiper/Washer Portion Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 1813 Multifunction Switch, Wiper/Washer Portion Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Multifunction Switch Wiper Switch: Diagrams Multifunction Switch Connector View C202a Connector View C202b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Multifunction Switch > Page 1818 Connector View C467 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Multifunction Switch > Page 1819 Connector View C2000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 1820 Wiper Switch: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 1821 Multifunction Switch, Wiper/Washer Portion Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 1822 Multifunction Switch, Wiper/Washer Portion Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 1823 Wiper Switch: Service and Repair REMOVAL 1. Remove the instrument panel finish panel. 1 Remove the screws. 2 Remove the center instrument panel finish panel. ^ Disconnect the electrical connectors. 2. Remove the rear wiper/washer switch. 1 Remove the screws. 2 Remove the mounting bezel. 3 Release the two tabs and remove the rear wiper/washer switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Alignment Procedure Revision Alignment: Technical Service Bulletins Steering/Suspension - Alignment Procedure Revision TSB 04-24-19 12/13/04 REVISED PROCEDURE FOR ADJUSTING ALIGNMENT ON ALL SUSPENSIONS - NEW RIGHT HAND UPPER CONTROL ARM DESIGN FOR TORSION BAR FRONT SUSPENSIONS FORD: 1998-2001 Explorer 1998-2003 Ranger 2000-2003 Explorer Sport 2001-2003 Explorer Sport Trac ISSUE The cam bolt and nut kit that was used for adjusting caster and camber on all torsion bar and coil spring front suspensions has been discontinued. If the caster and camber settings need to be adjusted, a washer must now be installed. The right hand upper control arm design changed from a two piece design to a single piece design during the 2003 model year. The single piece design is now the only version of the upper control arm available for service of prior model year Rangers. ACTION Use the following Camber And Caster Adjustment procedure when either camber or caster need to be adjusted on any suspension, or if only a caster split adjustment is needed on a vehicle equipped with single piece upper control arm. Use the following Caster Split Adjustment - Two Piece Right Hand Upper Control Arm procedure if only a caster split adjustment is needed on a vehicle equipped with a two piece upper control arm. SERVICE PROCEDURE CAMBER AND CASTER ADJUSTMENT NOTE THE UPPER CONTROL ARM-TO-FRAME MOUNTING BOLTS HAVE SET SHIMS THAT MUST BE REPLACED WITH WASHERS TO ALLOW FOR ADJUSTMENT OF THE ARM IN THE FRAME SLOT. THE VEHICLE SHOULD BE SUPPORTED BY THE LOWER CONTROL ARM TO EASE MOVEMENT OF THE UPPER ARM IN THE SLOT. 1. Remove and discard the upper control arm-to-frame nuts and shims (Figure 1). 2. Install new washers (W705040-5900) and nuts (N805480-5427). Tighten the nuts so there is tension, but the upper control arm can be moved for the alignment adjustment. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Alignment Procedure Revision > Page 1829 3. To adjust caster and camber refer to the chart. Adjustments that require moving the front and rear of the upper control arm should be made equally. 4. Torque the upper control arm-to-frame nuts to 98 lb.ft (133 N.m). 5. Check and if necessary adjust the front toe. Refer to the appropriate Workshop Manual for information. CASTER SPLIT ADJUSTMENT - TWO PIECE RIGHT HAND UPPER CONTROL ARM 1. To decrease the right hand caster, loosen the ball joint adjustment nuts (Figure 2) and move the ball joint forward. 2. To increase the right hand caster, loosen the ball joint adjustment nuts and move the ball joint rearward. 3. Torque the ball joint adjustment nuts to 129 lb.ft (175 N.m). 4. Check and if necessary adjust the front toe. Refer to the appropriate Workshop Manual for information. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 3084 07 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 1830 Alignment: Specifications Alignment Specifications Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 1831 General Specifications Torque Specifications Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 1832 Alignment: Description and Operation Wheel Alignment Angles Caster and camber are adjusted by means of eccentric cams on the upper control arm mounting bolts. Toe is adjusted by the use of the front wheel spindle tie-rod. Camber Negative and Positive Camber Negative and Positive Camber Camber is the vertical tilt of the wheel when viewed from the front. Camber can be positive or negative and has a direct effect on tire wear. Caster Caster is the deviation from vertical of an imaginary line drawn through the ball joints when viewed from the side. The caster specifications will give the vehicle the best directional stability characteristics when loaded and driven. The caster setting is not related to tire wear. Toe Positive Toe (Toe In) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 1833 Positive Toe (Toe In) Negative Toe (Toe Out) Negative Toe (Toe Out) The vehicle toe setting: ^ affects tire wear and directional stability. ^ must be checked after adding aftermarket equipment, such as a snowplow or body. Ride Height Front Ride Height Measurement Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 1834 Rear Ride Height Measurement Wheel Track Wheel Track Dogtracking Dogtracking Dogtracking is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can give the illusion of dogtracking. Wander Wander is the tendency of the vehicle to require frequent, random left and right steering wheel corrections to maintain a straight path down a level road. Shimmy Shimmy, as observed by the driver, is large, consistent, rotational oscillations of the steering wheel resulting from large, side-to-side (lateral) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 1835 tire/wheel movements. Shimmy is usually experienced near 64 km/h (40 mph), and can begin or be amplified when the tire contacts pot holes or irregularities in the road surface. Nibble Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with various road surfaces and observed by the driver as small rotational oscillations of the steering wheel. Poor Returnability/Sticky Steering Poor returnability and sticky steering is used to describe the poor return of the steering wheel to center after a turn or the steering correction is completed. Drift/Pull Pull is a tugging sensation, felt by the hands on the steering wheel, that must be overcome to keep the vehicle going straight. Drift describes what a vehicle with this condition does with hands off the steering wheel. ^ A vehicle-related drift/pull, on a flat road, will cause a consistent deviation from the straight-ahead path and require constant steering input in the opposite direction to counteract the effect. ^ Drift/pull may be induced by conditions external to the vehicle (i.e., wind, road camber). Poor Groove Feel Poor groove feel is characterized by little or no buildup of turning effort felt in the steering wheel as the wheel is rocked slowly left and right within very small turns around center or straight-ahead (under 20 degrees of steering wheel turn). Efforts may be said to be "flat on center." ^ Under 20 degrees of turn, most of the turning effort that builds up comes from the mesh of gear teeth in the steering gear. In this range, the steering wheel is not yet turned enough to feel the effort from the self-aligning forces at the road wheel or tire patch. ^ In the diagnosis of a readability problem, it is important to understand the difference between wander and poor groove feel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment Alignment: Service and Repair Camber and Caster Adjustment Camber and Caster Adjustment 1. Remove the nuts and alignment plates. 2. Install the cams and the nuts. 3. NOTE: A pry bar can be used between the front suspension arm bushing joint and the frame pocket to aid in moving the arm. To increase the LF caster and camber, use the following steps. 1 To increase caster, move the front of the front suspension arm bushing joint outboard and move the rear of the front suspension arm bushing joint inboard. 2 To increase camber, move the front suspension arm bushing joint outboard equally. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 1838 4. To decrease the LF caster and camber, use the following steps. 1 To decrease caster, move the front of the front suspension arm bushing joint inboard and move the rear of the front suspension arm bushing joint outboard. 2 To decrease camber, move the front suspension arm bushing joint inboard equally. 5. Tighten the nuts. 6. NOTE: A pry bar can be used between the front suspension arm bushing joint and the frame pocket to aid in moving the arm. To increase RF caster and camber, use the following steps. 1 To increase-caster, move the front of the front suspension arm bushing joint outboard and move the rear of the front suspension arm bushing joint inboard. 2 To increase camber, move the front suspension arm bushing joint outboard equally. 7. To decrease the RF caster and camber, use the following steps. 1 To decrease caster, move the front of the front suspension arm bushing joint inboard and move the rear of the front suspension arm bushing joint outboard. 2 To decrease camber, move the front suspension arm bushing joint inboard equally. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 1839 8. Increase the caster split. 1 Loosen the nuts. 2 Adjust the caster set bolts forward. 9. Decrease the caster split. 1 Loosen the nuts. 2 Adjust the caster set bolts rearward. 10. Tighten the nuts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 1840 Alignment: Service and Repair Toe Adjustment Toe Adjustment 1. Start the engine and center the steering wheel. 2. Turn the engine off, and hold the steering wheel in the "straight forward" position by attaching a rigid link from the steering wheel to the brake pedal. 3. Check the toe settings; follow the manufacturer's instructions. 4. NOTE: Do not allow the steering gear bellows to twist when the front wheel spindle tie-rod is rotated. Remove the clamps. 5. Loosen the nuts. ^ Clean and lubricate the nut(s) and front wheel spindle tie-rod threads. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 1841 6. Rotate the front wheel spindle tie-rods. 7. Tighten the nuts. 8. Install the clamps. 9. Recheck the toe settings; follow the manufacturer's instructions. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Technician Safety Information Fuel Pressure Test Port: Technician Safety Information WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Technician Safety Information > Page 1848 Fuel Pressure Test Port: Vehicle Damage Warnings CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 1849 Fuel Pressure Test Port: Description and Operation Pressure Test Point There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. ON VEHICLES NOT EQUIPPED WITH A SCHRADER VALVE, USE ROTUNDA FUEL PRESSURE TEST KIT #134-R0087 OR EQUIVALENT. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 1850 Fuel Pressure Test Port: Service and Repair REMOVAL WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Remove the fuel injection supply manifold. 2. Remove the two bolts, the pressure relief valve and the O-ring seals. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. NOTE: Lubricate the new O-ring seals with clean engine oil to aid installation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > With Automatic Transmission Idle Speed: Specifications With Automatic Transmission With Flex Fuel Hot Idle ................................................................................................................................................ ......................................................... 800 - 900 RPM With Gasoline Hot Idle ................................................................................................................................................ ......................................................... 760 - 780 RPM Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > With Automatic Transmission > Page 1855 Idle Speed: Specifications With Manual Transmission Hot Idle ................................................................................................................................................ ......................................................... 760 - 880 RPM Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Service and Repair Air Cleaner Housing: Service and Repair REMOVAL 1. Disconnect the air cleaner assembly. ^ Loosen the clamp and disconnect the outlet tube. ^ Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Remove the lower air cleaner assembly. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1863 Fuel Pressure Release: Service and Repair Fuel Pressure Gauge SPECIAL TOOL(S) WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Disconnect the battery ground cable. 2. Remove the Schrader valve cap and attach the Fuel Pressure Gauge. 3. Open the manual valve on the Fuel Pressure Gauge slowly to relieve the fuel system pressure. This may drain fuel from the system. Drain the fuel into a suitable container. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1864 Fuel Pressure Gauge Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Coil Terminal-To-Cylinder Relationship Firing order........................................................................................................................................... ..................................................................1-4-2-5-3-6 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 1868 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 05-10-3 > May > 05 > Interior Accelerator Pedal Vibration at 1500-1800 RPM Ignition Cable: Customer Interest Interior - Accelerator Pedal Vibration at 1500-1800 RPM TSB 05-10-3 05/30/05 ACCELERATOR PEDAL VIBRATION/BUZZ AT 1500-1800 RPM FORD: 2001-2005 Explorer Sport Trac ISSUE Some 2001-2005 Explorer Sport Trac vehicles may exhibit the accelerator pedal vibrating or buzzing at 1500-1800 RPM. ACTION Ensure the accelerator cable and the hood release cables are not contacting the # 6 spark plug wire. Reposition cables as needed. Also, ensure that the accelerator cable is secure in the retention clip, and that the clip's spring tensioner is on top. Refer to Figure 1 (incorrect position) and Figure 2 (correct position). WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9A758 43 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 05-10-3 > May > 05 > Interior Accelerator Pedal Vibration at 1500-1800 RPM > Page 1881 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 05-10-3 > May > 05 > Interior - Accelerator Pedal Vibration at 1500-1800 RPM Ignition Cable: All Technical Service Bulletins Interior - Accelerator Pedal Vibration at 1500-1800 RPM TSB 05-10-3 05/30/05 ACCELERATOR PEDAL VIBRATION/BUZZ AT 1500-1800 RPM FORD: 2001-2005 Explorer Sport Trac ISSUE Some 2001-2005 Explorer Sport Trac vehicles may exhibit the accelerator pedal vibrating or buzzing at 1500-1800 RPM. ACTION Ensure the accelerator cable and the hood release cables are not contacting the # 6 spark plug wire. Reposition cables as needed. Also, ensure that the accelerator cable is secure in the retention clip, and that the clip's spring tensioner is on top. Refer to Figure 1 (incorrect position) and Figure 2 (correct position). WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9A758 43 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 05-10-3 > May > 05 > Interior - Accelerator Pedal Vibration at 1500-1800 RPM > Page 1887 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 1888 Ignition Cable: Service Precautions CAUTION: ^ Spark plug wires must be connected correctly. Mark the spark plug wires before removing them. ^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. ^ Be sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifold. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 1889 Ignition Cable: Service and Repair Spark Plug Wire Remover SPECIAL TOOL(S) REMOVAL 1. Remove the right front tire. 2. Remove the right front fenderwell splash shield. 3. With a twisting motion, use the special tool to pull the spark plug wires from the right side of the engine. CAUTION: ^ Spark plug wires must be connected correctly. Mark the spark plug wires before removing them. ^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. 4. Lower the vehicle. 5. With a twisting motion, use the special tool to pull the spark plug wires from the left side of the engine. CAUTION: ^ Spark plug wires must be connected correctly. Mark the spark plug wires before removing them. ^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 1890 6. Squeeze the locking tabs and twist while pulling upward to remove the spark plug wires from the ignition coil. 7. Disconnect the spark plug wires from the separators and remove the spark plug wires. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Be sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifold. NOTE: Apply silicone dielectric compound to the inside of the spark plug and ignition coil boots of the spark plug wire. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 1891 Spark Plug Wire Remover Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Spark Plug: Specifications Gap Item....................................................................................................................................................... ..............................................................Specification Spark plug gap..................................................................................................................................... ....................................1.57-1.73 mm (0.061-0.068 in) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap > Page 1896 Spark Plug: Specifications Torque Item....................................................................................................................................................... ..............................................................Specification Spark plug............................................................................................................................................ .........................................................17 Nm (13 Lb-Ft) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1897 Spark Plug: Application and ID Item....................................................................................................................................................... ..............................................................Specification Spark plug type..................................................................................................................................... ..................................................................AGSF34FP Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1898 Spark Plug: Service and Repair REMOVAL 1. Remove the spark plug wires from the spark plugs. 2. Remove the spark plugs. NOTE: ^ Use compressed air to remove any foreign material in the spark plug well before removing the spark plugs. ^ If an original spark plug is reused, make sure it is installed in the same cylinder it was taken from. New spark plugs can be used in any cylinder. 3. Inspect the spark plugs. 4. Use a suitable spark plug gap tool to check and adjust the spark plug gap. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Pressure Limit Chart The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1902 Compression Check: Testing and Inspection Compression Test-Compression Gauge Check 1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level and that the battery is correctly charged. Operate the vehicle until the engine is at normal operating temperature. Turn the ignition switch to the OFF position, then remove all the spark plugs. 2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the Compression Tester in the No. 1 cylinder. 4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position, and using the auxiliary starter switch, crank the engine a minimum of five compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Compression Test-Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Compression Test-Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. 2. If compression does not improve, valves are sticking or seating incorrectly. 3. If two adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1903 Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is within 75 percent of the highest reading. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair Drive Belt: Service and Repair Accessory Drive Belt Removal and Installation 1. Remove the air cleaner outlet tube. 2. Remove the accessory drive belt. 1 Rotate the accessory drive belt tensioner counterclockwise. 2 Remove the belt. 3. NOTE: Refer to Component locations for correct drive belt routing. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Component Information > Service and Repair Air Cleaner Housing: Service and Repair REMOVAL 1. Disconnect the air cleaner assembly. ^ Loosen the clamp and disconnect the outlet tube. ^ Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Remove the lower air cleaner assembly. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair Cabin Air Filter: Service and Repair NOTE: The air distribution system of this vehicle cannot be equipped with a cabin air filter. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Service Precautions Evaporative Canister Filter: Service Precautions WARNING: ^ THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL ARE PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Service and Repair > Vehicles Built Before 03/2002 Evaporative Canister Filter: Service and Repair Vehicles Built Before 03/2002 REMOVAL 1. Open the liftgate lower and remove the spare tire. 2. Disconnect the battery ground cable. WARNING: THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL ARE PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 3. Disconnect the two chassis emissions lines from the evaporative emission tube. WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 4. Remove the evaporative emissions canister bolts. 5. Remove the evaporative emission canister with bracket assembly. 1 Disconnect the canister vent solenoid electrical connector. 2 Remove the EVAP canister with bracket assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Service and Repair > Vehicles Built Before 03/2002 > Page 1919 6. Disconnect the canister vent solenoid hose assembly. 7. Remove the evaporative emission dust separator. INSTALLATION 1. To install, reverse the removal procedure. ^ Leak test the evaporative emission system. See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Evaporative Emission Repair Verification Drive Cycle Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Service and Repair > Vehicles Built Before 03/2002 > Page 1920 Evaporative Canister Filter: Service and Repair Vehicles After Before 03/2002 REMOVAL WARNING: ^ THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, WHICH CAN CAUSE A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUEFIED FUEL ARE PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY. ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND CAN BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY. 1. Remove the evaporative emissions canister. 2. Remove the emissions hose. 3. Remove the dust separator. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 01-22-3 > Nov > 01 > A/T - Buzzing Noise When Torque Converter Engaged Fluid Filter - A/T: Customer Interest A/T - Buzzing Noise When Torque Converter Engaged Article No. 01-22-3 11/12/01 ^ NOISE - BUZZING NOISE FROM THE TRANSMISSION WHEN THE TORQUE CONVERTER IS ENGAGED - VEHICLES PRODUCED 11/15/2000 THROUGH 11/11/2001 EQUIPPED WITH 4.6L ENGINE AND 5R55W TRANSMISSION ONLY ^ TRANSMISSION - 5R55W - BUZZING NOISE FROM THE TRANSMISSION WHEN THE TORQUE CONVERTER IS ENGAGED - VEHICLES PRODUCED 11/15/2000 THROUGH 11/11/2001 EQUIPPED WITH 4.6L ENGINE ONLY FORD: 2002 EXPLORER MERCURY: 2002 MOUNTAINEER ISSUE Some vehicles built prior to 11/11/2001 equipped with 5R55W and 4.6L engine, may exhibit a buzzing noise when the torque converter is engaged and the transmission fluid temperature is between 38-66°C (100-150 °F). This may be caused by a high velocity of fluid flow in the Main Control. ACTION Verity that the condition exists using the procedure listed. If the conditions described are verified, the Main Control will need to be replaced. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE THIS ARTICLE DOES NOT APPLY TO ANY OTHER CONDITIONS OR COMPONENTS THAT MAY CAUSE SIMILAR SYMPTOMS. 1. To verity that the condition exists with the vehicle, first connect a tachometer to the engine if the vehicle is not already equipped. 2. Install an NGS or equivalent and monitor the Transmission Fluid Temperature (TFT). 3. Start the engine and drive the vehicle. 4. When the TFT reaches 38°C (100 °F), maintain a constant speed of about 80 km/h (50 mph) to engage the converter. Tap the brake pedal with the left foot. Engine RPM should increase when the brake pedal has been tapped, and decrease after about five seconds after the pedal is released. 5. Maintaining a constant vehicle speed, allow the torque converter to re-engage. 6. Listen for the Torque Converter Clutch buzzing noise. Is the noise present? ^ If yes, continue with the verification. ^ If no, follow normal diagnosis as listed in the Workshop Manual, the Main Control is not the problem. 7. Continue to bring the transmission to operating temperature above 66°C (150°F). This may be accomplished by driving the vehicle for 15 to 20 minutes. 8. After normal operating temperature is reached, maintain a constant speed of about 80 km/h (50 mph) to engage the converter. Tap the brake pedal with the left foot. Engine RPM should increase when the brake pedal has been tapped, and decrease after about five seconds after the pedal is released. 9. Maintaining a constant vehicle speed, allow the torque converter to re-engage. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 01-22-3 > Nov > 01 > A/T - Buzzing Noise When Torque Converter Engaged > Page 1929 10. Listen for the Torque Converter Clutch buzzing noise. Has the noise disappeared? ^ If yes, continue. ^ If no, follow normal diagnosis as listed in the Workshop Manuals, the Main Control is not the problem. 11. If the condition exists, drain the transmission fluid from the pan. NOTE AN IN-LINE SERVICE FILTER IS NOT REQUIRED TO BE ADDED OR REPLACED FOR THIS ARTICLE. 12. Replace the Main Control 1L2Z-7A100-CA and Fluid Filter 1L2Z-7A098-AC. Follow the steps listed in the Workshop Manual, In-Vehicle Service, Main Control Valve Body, to remove and replace. 13. Verify the condition has been corrected. 14. Clear all DTCs. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 012203A Verify Conditions And 2.6 Hrs. Replace Transmission Main Control DEALER CODING CONDITION BASIC PART NO. CODE 7A100 42 OASIS CODES: 504000, 702000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 01-20-7 > Oct > 01 > A/T - 5R55W Ticking Noise Fluid Filter - A/T: Customer Interest A/T - 5R55W Ticking Noise Article No. 01-20-7 10/15/01 ^ NOISE -"TICK" NOISE FROM TRANSMISSION FRONT OR INTERMEDIATE SERVO COVER AREA - VEHICLES EQUIPPED WITH 5R55W TRANSMISSION - VEHICLES PRODUCED PRIOR TO 9/6/2001 ^ TRANSMISSION - 5R55W -"TICK" NOISE FROM TRANSMISSION FRONT OR INTERMEDIATE SERVO COVER AREA - VEHICLES PRODUCED PRIOR TO 9/6/2001 FORD: 2002 EXPLORER MERCURY: 2002 MOUNTAINEER ISSUE Some vehicles produced before 9/6/2001 equipped with the 5R55W transmission, may exhibit a tick noise emanating from the Front or Intermediate Servo Cover. This tick noise is only present at Idle in Park or Neutral. ACTION Verify that the condition exists and the noise is emanating from the Front or Intermediate Servo. If so, the Separator Plate 7Z490 or the Main Control may need to be replaced. Follow the service procedures for the repair. SERVICE PROCEDURE This TSB does not apply to any other ticking noises from transmission and vehicle components or locations. NOTE DO NOT ADD THE IN-LINE SERVICE FILTER AS LISTED IN THE WORKSHOP MANUAL. THE IN-LINE FILTER IS NOT REQUIRED TO BE ADDED FOR THIS TSB. 1. Verify that the condition exists ONLY during the following conditions: - at Idle, - while in Park and Neutral, - with the noise emanating from the Front or Intermediate Servos. 2. If the condition exists, drain the transmission fluid from the pan. 3. Remove the fluid pan and fluid pan gasket (the gasket is reusable). 4. Inspect the fluid in pan for major contamination. If major contamination is present, the Main Control (7A100) and Fluid Filter will need to be replaced. 5. If major contamination is not present, only the Main Control Separating Plate and fluid filter need to be replaced. 6. To replace ONLY the Main Control (7A100) and Fluid Filter (7A098), follow the steps listed in the Workshop Manual In-Vehicle Service, Main Control Valve Body, to remove and replace. 7. To replace ONLY the Main Control Separating Plate (7Z490) and Fluid Filter (7A098), follow the removal steps listed in the Workshop Manual In-Vehicle Service, Main Control Valve Body. 8. Once the Main Control Valve Body has been removed, rotate the body so that the separator is up and place on a clean work surface. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 01-20-7 > Oct > 01 > A/T - 5R55W Ticking Noise > Page 1934 9. Remove the three screws that attach the plate to the main control, remove and discard the plate (Figure 1). 10. Make sure that the check balls are in there proper location (Figure 2). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 01-20-7 > Oct > 01 > A/T - 5R55W Ticking Noise > Page 1935 11. lnstall the Special Service Tools 307-334 (2 required) on to the main control (Figure 3). 12. Install a NEW service Separator Plate, install the three (3) screws and tighten to 10 Nm (89 lb-in). Remove the Special Service Tools. 13. Reinstall the Main Control by continuing to follow the Installation steps listed in the Workshop Manual In-Vehicle Service, Main Control Valve Body. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 012007A Replace Main Control 1.8 Hrs. Valve Body And Fluid Filter 012007B Replace Main Control 1.9 Hrs. Valve Body Separator Plate And Fluid Filter DEALER CODING CONDITION BASIC PART NO. CODE 7Z490 42 OASIS CODES: 504000, 597997, 702000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 01-14-2 > Jul > 01 > A/T - 5R55W Whine/Howl When Cold Fluid Filter - A/T: Customer Interest A/T - 5R55W Whine/Howl When Cold Article No. 01-14-2 07/23/01 ^ NOISE - "WHINE" OR "HOWL" NOISE FROM TRANSMISSION AT START-UP TEMPERATURES BELOW 4 C (40 F) - VEHICLES EQUIPPED WITH 5R55W TRANSMISSION PRODUCED 11/13/2000 THROUGH 8/1/2001 ONLY ^ TRANSMISSION - 5R55W - "WHINE" OR "HOWL" NOISE FROM TRANSMISSION AT START-UP - TEMPERATURES BELOW 4 C (40 F) - PRODUCED 11/13/2000 THROUGH 8/1/2001 ONLY FORD: 2002 EXPLORER MERCURY: 2002 MOUNTAINEER ISSUE Some vehicles, built prior to 8/01/2001, may exhibit a "whine" or "howl" noise during cold starts at temperatures below 4° C (40°F). This noise may be caused by the transmission fluid filter. ACTION Verify that the noise ONLY occurs during start up with ambient temperatures below 4°C (40 °F). If the noise is present only under those conditions replace the transmission fluid filter. Refer to the following Service Procedures for details. SERVICE PROCEDURE 1. Raise vehicle on a hoist. 2. Drain the fluid from the pan. 3. Remove the pan and gasket. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 01-14-2 > Jul > 01 > A/T - 5R55W Whine/Howl When Cold > Page 1940 4. Replace the original filter with the new service filter 1L2Z-7A098-AC (Figure 1). 5. Clean the pan. 6. Reinstall the fluid pan gasket and pan. Tighten the screws in a crisscross pattern to 11 N.m (8 lb-ft). 7. Add fluid and adjust to the proper level, refer to the workshop manual procedure, Fluid Level Check. 8. If the noise is still present after the fluid filter has been replaced, follow normal diagnosis for noise concerns using the Diagnosis by Symptom Charts in the Workshop Manual (Section 307-01). Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011402A Replace Transmission 1.0 Hr. Fluid Filter DEALER CODING CONDITION BASIC PART NO. CODE 7A098 42 OASIS CODES: 501000, 502000, 503000, 504000, 702000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 01-22-3 > Nov > 01 > A/T - Buzzing Noise When Torque Converter Engaged Fluid Filter - A/T: All Technical Service Bulletins A/T - Buzzing Noise When Torque Converter Engaged Article No. 01-22-3 11/12/01 ^ NOISE - BUZZING NOISE FROM THE TRANSMISSION WHEN THE TORQUE CONVERTER IS ENGAGED - VEHICLES PRODUCED 11/15/2000 THROUGH 11/11/2001 EQUIPPED WITH 4.6L ENGINE AND 5R55W TRANSMISSION ONLY ^ TRANSMISSION - 5R55W - BUZZING NOISE FROM THE TRANSMISSION WHEN THE TORQUE CONVERTER IS ENGAGED - VEHICLES PRODUCED 11/15/2000 THROUGH 11/11/2001 EQUIPPED WITH 4.6L ENGINE ONLY FORD: 2002 EXPLORER MERCURY: 2002 MOUNTAINEER ISSUE Some vehicles built prior to 11/11/2001 equipped with 5R55W and 4.6L engine, may exhibit a buzzing noise when the torque converter is engaged and the transmission fluid temperature is between 38-66°C (100-150 °F). This may be caused by a high velocity of fluid flow in the Main Control. ACTION Verity that the condition exists using the procedure listed. If the conditions described are verified, the Main Control will need to be replaced. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE THIS ARTICLE DOES NOT APPLY TO ANY OTHER CONDITIONS OR COMPONENTS THAT MAY CAUSE SIMILAR SYMPTOMS. 1. To verity that the condition exists with the vehicle, first connect a tachometer to the engine if the vehicle is not already equipped. 2. Install an NGS or equivalent and monitor the Transmission Fluid Temperature (TFT). 3. Start the engine and drive the vehicle. 4. When the TFT reaches 38°C (100 °F), maintain a constant speed of about 80 km/h (50 mph) to engage the converter. Tap the brake pedal with the left foot. Engine RPM should increase when the brake pedal has been tapped, and decrease after about five seconds after the pedal is released. 5. Maintaining a constant vehicle speed, allow the torque converter to re-engage. 6. Listen for the Torque Converter Clutch buzzing noise. Is the noise present? ^ If yes, continue with the verification. ^ If no, follow normal diagnosis as listed in the Workshop Manual, the Main Control is not the problem. 7. Continue to bring the transmission to operating temperature above 66°C (150°F). This may be accomplished by driving the vehicle for 15 to 20 minutes. 8. After normal operating temperature is reached, maintain a constant speed of about 80 km/h (50 mph) to engage the converter. Tap the brake pedal with the left foot. Engine RPM should increase when the brake pedal has been tapped, and decrease after about five seconds after the pedal is released. 9. Maintaining a constant vehicle speed, allow the torque converter to re-engage. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 01-22-3 > Nov > 01 > A/T - Buzzing Noise When Torque Converter Engaged > Page 1946 10. Listen for the Torque Converter Clutch buzzing noise. Has the noise disappeared? ^ If yes, continue. ^ If no, follow normal diagnosis as listed in the Workshop Manuals, the Main Control is not the problem. 11. If the condition exists, drain the transmission fluid from the pan. NOTE AN IN-LINE SERVICE FILTER IS NOT REQUIRED TO BE ADDED OR REPLACED FOR THIS ARTICLE. 12. Replace the Main Control 1L2Z-7A100-CA and Fluid Filter 1L2Z-7A098-AC. Follow the steps listed in the Workshop Manual, In-Vehicle Service, Main Control Valve Body, to remove and replace. 13. Verify the condition has been corrected. 14. Clear all DTCs. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 012203A Verify Conditions And 2.6 Hrs. Replace Transmission Main Control DEALER CODING CONDITION BASIC PART NO. CODE 7A100 42 OASIS CODES: 504000, 702000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 01-20-7 > Oct > 01 > A/T - 5R55W Ticking Noise Fluid Filter - A/T: All Technical Service Bulletins A/T - 5R55W Ticking Noise Article No. 01-20-7 10/15/01 ^ NOISE -"TICK" NOISE FROM TRANSMISSION FRONT OR INTERMEDIATE SERVO COVER AREA - VEHICLES EQUIPPED WITH 5R55W TRANSMISSION - VEHICLES PRODUCED PRIOR TO 9/6/2001 ^ TRANSMISSION - 5R55W -"TICK" NOISE FROM TRANSMISSION FRONT OR INTERMEDIATE SERVO COVER AREA - VEHICLES PRODUCED PRIOR TO 9/6/2001 FORD: 2002 EXPLORER MERCURY: 2002 MOUNTAINEER ISSUE Some vehicles produced before 9/6/2001 equipped with the 5R55W transmission, may exhibit a tick noise emanating from the Front or Intermediate Servo Cover. This tick noise is only present at Idle in Park or Neutral. ACTION Verify that the condition exists and the noise is emanating from the Front or Intermediate Servo. If so, the Separator Plate 7Z490 or the Main Control may need to be replaced. Follow the service procedures for the repair. SERVICE PROCEDURE This TSB does not apply to any other ticking noises from transmission and vehicle components or locations. NOTE DO NOT ADD THE IN-LINE SERVICE FILTER AS LISTED IN THE WORKSHOP MANUAL. THE IN-LINE FILTER IS NOT REQUIRED TO BE ADDED FOR THIS TSB. 1. Verify that the condition exists ONLY during the following conditions: - at Idle, - while in Park and Neutral, - with the noise emanating from the Front or Intermediate Servos. 2. If the condition exists, drain the transmission fluid from the pan. 3. Remove the fluid pan and fluid pan gasket (the gasket is reusable). 4. Inspect the fluid in pan for major contamination. If major contamination is present, the Main Control (7A100) and Fluid Filter will need to be replaced. 5. If major contamination is not present, only the Main Control Separating Plate and fluid filter need to be replaced. 6. To replace ONLY the Main Control (7A100) and Fluid Filter (7A098), follow the steps listed in the Workshop Manual In-Vehicle Service, Main Control Valve Body, to remove and replace. 7. To replace ONLY the Main Control Separating Plate (7Z490) and Fluid Filter (7A098), follow the removal steps listed in the Workshop Manual In-Vehicle Service, Main Control Valve Body. 8. Once the Main Control Valve Body has been removed, rotate the body so that the separator is up and place on a clean work surface. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 01-20-7 > Oct > 01 > A/T - 5R55W Ticking Noise > Page 1951 9. Remove the three screws that attach the plate to the main control, remove and discard the plate (Figure 1). 10. Make sure that the check balls are in there proper location (Figure 2). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 01-20-7 > Oct > 01 > A/T - 5R55W Ticking Noise > Page 1952 11. lnstall the Special Service Tools 307-334 (2 required) on to the main control (Figure 3). 12. Install a NEW service Separator Plate, install the three (3) screws and tighten to 10 Nm (89 lb-in). Remove the Special Service Tools. 13. Reinstall the Main Control by continuing to follow the Installation steps listed in the Workshop Manual In-Vehicle Service, Main Control Valve Body. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 012007A Replace Main Control 1.8 Hrs. Valve Body And Fluid Filter 012007B Replace Main Control 1.9 Hrs. Valve Body Separator Plate And Fluid Filter DEALER CODING CONDITION BASIC PART NO. CODE 7Z490 42 OASIS CODES: 504000, 597997, 702000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 01-14-2 > Jul > 01 > A/T - 5R55W Whine/Howl When Cold Fluid Filter - A/T: All Technical Service Bulletins A/T - 5R55W Whine/Howl When Cold Article No. 01-14-2 07/23/01 ^ NOISE - "WHINE" OR "HOWL" NOISE FROM TRANSMISSION AT START-UP TEMPERATURES BELOW 4 C (40 F) - VEHICLES EQUIPPED WITH 5R55W TRANSMISSION PRODUCED 11/13/2000 THROUGH 8/1/2001 ONLY ^ TRANSMISSION - 5R55W - "WHINE" OR "HOWL" NOISE FROM TRANSMISSION AT START-UP - TEMPERATURES BELOW 4 C (40 F) - PRODUCED 11/13/2000 THROUGH 8/1/2001 ONLY FORD: 2002 EXPLORER MERCURY: 2002 MOUNTAINEER ISSUE Some vehicles, built prior to 8/01/2001, may exhibit a "whine" or "howl" noise during cold starts at temperatures below 4° C (40°F). This noise may be caused by the transmission fluid filter. ACTION Verify that the noise ONLY occurs during start up with ambient temperatures below 4°C (40 °F). If the noise is present only under those conditions replace the transmission fluid filter. Refer to the following Service Procedures for details. SERVICE PROCEDURE 1. Raise vehicle on a hoist. 2. Drain the fluid from the pan. 3. Remove the pan and gasket. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 01-14-2 > Jul > 01 > A/T - 5R55W Whine/Howl When Cold > Page 1957 4. Replace the original filter with the new service filter 1L2Z-7A098-AC (Figure 1). 5. Clean the pan. 6. Reinstall the fluid pan gasket and pan. Tighten the screws in a crisscross pattern to 11 N.m (8 lb-ft). 7. Add fluid and adjust to the proper level, refer to the workshop manual procedure, Fluid Level Check. 8. If the noise is still present after the fluid filter has been replaced, follow normal diagnosis for noise concerns using the Diagnosis by Symptom Charts in the Workshop Manual (Section 307-01). Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011402A Replace Transmission 1.0 Hr. Fluid Filter DEALER CODING CONDITION BASIC PART NO. CODE 7A098 42 OASIS CODES: 501000, 502000, 503000, 504000, 702000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Page 1958 Fluid Filter - A/T: Specifications Transmission fluid filter screws .................................................................................................................................................... 8-11 Nm (71-97 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Page 1959 Fluid Filter - A/T: Service and Repair Fluid Pan, Gasket and Filter Removal 1. Position the vehicle on a hoist. Place in NEUTRAL. 2. NOTE: If equipped, the transmission servo heat shield must be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. If equipped, loosen the nut and position the heat shield out of the way. 3. Place a drain pan under the transmission fluid pan. 4. Drain transmission fluid. - Remove all the transmission fluid pan bolts except for two in the front. Loosen the two front transmission fluid pan screws. Pry the rear of the transmission fluid pan down and allow fluid to drain. After fluid is drained, remove the front two transmission fluid pan screws. 5. Remove the transmission fluid pan. 1 Remove the transmission fluid pan. 2 Remove and discard the transmission fluid pan gasket. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Page 1960 6. Remove and discard the transmission fluid filter. 1 Remove the transmission fluid filter screw. 2 Remove the transmission fluid filter. 7. Clean and inspect the transmission fluid pan and magnet. Clean all mating surfaces. 8. Flush the transmission fluid cooler and transmission fluid cooler lines. Installation 1. CAUTION: Lubricate fluid filter O-ring seals with clean automatic transmission fluid or they can be damaged if; Lube and install new O-ring seals onto the transmission fluid filter. Install a new transmission fluid filter. Position the transmission fluid filter on the main control valve body. 2. Install the transmission fluid filter. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Page 1961 3. Position the oil pan magnet in the transmission fluid pan. 4. Install the transmission fluid pan. 1 Position a new transmission fluid pan gasket on the transmission fluid pan. 2 Install and align the transmission fluid pan. - Loosely install the transmission fluid pan screws. 5. Tighten the transmission fluid pan screws. - Tighten the transmission fluid pan screws in a crisscross sequence. 6. If equipped, position the servo heat shield over the servos and clip it to the pan rail. 7. Lower the vehicle. 8. Apply the park brake, and start the engine. 9. NOTE: When filling a dry transmission and converter, start with a minimum of 3.7 liters (4 quarts). Fill transmission with clean automatic transmission fluid to the correct fluid level and check for correct transmission operation. 10. Move the range selector lever through all the gears. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Page 1962 11. Recheck the transmission fluid level. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1967 Fuel Pressure Release: Service and Repair Fuel Pressure Gauge SPECIAL TOOL(S) WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Disconnect the battery ground cable. 2. Remove the Schrader valve cap and attach the Fuel Pressure Gauge. 3. Open the manual valve on the Fuel Pressure Gauge slowly to relieve the fuel system pressure. This may drain fuel from the system. Drain the fuel into a suitable container. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1968 Fuel Pressure Gauge Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications Oil Filter: Specifications Oil bypass filter .................................................................................................................................... .................................................... 13 Nm (10 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 1981 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 1982 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 1988 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 1989 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 04-25-11 > Dec > 04 > A/C - Moaning From Engine Compartment Hose/Line HVAC: Customer Interest A/C - Moaning From Engine Compartment TSB 04-25-11 12/27/04 MOAN/VIBRATION DURING A/C OPERATION FORD: 2001-2005 Explorer Sport Trac ISSUE Some 2001-2005 Explorer Sport Trac vehicles may exhibit a moan/vibration coming from the engine compartment while the A/C is on and the engine is at low RPM. The noise will only occur when the A/C compressor is running. ACTION Replace the manifold and tube assembly on the A/C compressor. Refer to Workshop Manual Section 412-03. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042511A Replace The Manifold And 1.7 Hrs. Tube Assembly On The A/C Compressor (Includes Time To Recover, Evacuate And Charge The Air Conditioning System) DEALER CODING CONDITION BASIC PART NO. CODE 19D734 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 04-25-11 > Dec > 04 > A/C - Moaning From Engine Compartment Hose/Line HVAC: All Technical Service Bulletins A/C - Moaning From Engine Compartment TSB 04-25-11 12/27/04 MOAN/VIBRATION DURING A/C OPERATION FORD: 2001-2005 Explorer Sport Trac ISSUE Some 2001-2005 Explorer Sport Trac vehicles may exhibit a moan/vibration coming from the engine compartment while the A/C is on and the engine is at low RPM. The noise will only occur when the A/C compressor is running. ACTION Replace the manifold and tube assembly on the A/C compressor. Refer to Workshop Manual Section 412-03. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042511A Replace The Manifold And 1.7 Hrs. Tube Assembly On The A/C Compressor (Includes Time To Recover, Evacuate And Charge The Air Conditioning System) DEALER CODING CONDITION BASIC PART NO. CODE 19D734 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Page 2003 Hose/Line HVAC: Description and Operation NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. The condenser to evaporator tube contains high pressure liquid refrigerant upstream of the A/C evaporator core orifice. The A/C manifold and tube is attached to the A/C compressor, is sealed with O-ring seals, and has the following features: - The upstream side contains low pressure refrigerant gas. - The downstream side contains high pressure refrigerant gas and a fitting used to mount a serviceable high-pressure A/C charge port valve. - The downstream side also contains a fitting used to mount the A/C pressure cutoff switch. A long-travel Schrader-type valve stem core is installed in the fitting so that the A/C pressure cutoff switch can be removed without discharging the A/C system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Page 2004 Hose/Line HVAC: Service and Repair REMOVAL 1. Prepare the vehicle for condenser to evaporator tube removal. 1 Disconnect the battery ground cable. 2 Recover the refrigerant. 3 Remove the air cleaner assembly. 2. Disconnect the condenser to evaporator tube from the A/C condenser core. Remove and discard the O-ring seal. - During installation, install a new O-ring seal lubricated with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B. 3. Disconnect and remove the condenser to evaporator tube. INSTALLATION 1. To install, reverse the removal procedure. 2. Evacuate, leak test, and charge the A/C system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications Power Steering Pressure Hose To Power Steering Pump ......................................................................................................................... 65 Nm (48 ft. lbs.) Steering Line To Gear Clamp Plate Nut ................................................................................................................................................... 25 Nm (18 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications > Page 2008 Power Steering Line/Hose: Service and Repair Hose Special Tools Special Tool(s) Removal and Installation CAUTION: While servicing the power steering system, make sure to plug all open hoses, line fittings, and fluid ports to prevent the entry of contaminants or premature failure of the power steering components can result. 1. Refer to the System View illustration for the hose routing and retention points. 2. When connecting a fitting with a seal ring, a new seal ring must be installed. ^ The special tool is used to install the return line connector seal and the pressure line connector seal. 3. Fill, purge and leak check the system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications High Performance DOT 3 Brake Fluid .............................................................................. C6AZ-19542-AB or meets Ford specification ESA-M6C25-A. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Specifications Clutch Fluid: Specifications High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB 3ESA-M6C25-A Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - Premium Gold Coolant Service Info Coolant: Technical Service Bulletins Cooling System - Premium Gold Coolant Service Info Article No. 02-23-7 11/25/02 COOLING SYSTEM - MOTORCRAFT PREMIUM GOLD ENGINE COOLANT - SERVICE TIPS FORD: 2002-2003 ESCORT ZX2, FOCUS, MUSTANG, TAURUS, THUNDERBIRD 2003 CROWN VICTORIA 2002 EXCURSION 2002-2003 E SERIES, ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT, EXPLORER, F-150, RANGER, SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS. 2003 EXPEDITION, WINDSTAR 2002-2003 F-650, F-750 LINCOLN: 2002 CONTINENTAL 2002-2003 LS 2003 TOWN CAR 2002-2003 BLACKWOOD 2003 AVIATOR, NAVIGATOR MERCURY: 2002-2003 SABLE 2003 GRAND MARQUIS 2002-2003 MOUNTAINEER Article 02-17-7 is being republished in its entirety to update the text and part numbers. ISSUE A new, extended-life engine coolant, yellow-colored Motorcraft Premium Gold Engine Coolant, meeting Ford Specification WSS-M97B51-A1, service part numbers VC-7-A and VC-7-C (for use in the U.S., except California and Oregon) and VC-7-B (for use only in California and Oregon as it contains a bittering agent), has been equipped in all of the vehicles noted above. The initial-fill life for this coolant is 100,000 miles/5 years. Due to variations in water quality, the replacement interval is 50,000 miles/3 years. ACTION Any time the addition of coolant or a coolant change-out is required, USE ONLY THE TYPE OF ENGINE COOLANT WITH WHICH THE VEHICLE WAS ORIGINALLY EQUIPPED. DO NOT MIX COOLANT TYPES. To determine the type of coolant required, check the color of coolant in the coolant reservoir of the vehicle or refer to the applicable vehicle's Owner's Guide or Workshop Manual for service parts and specification information. SERVICE INFORMATION Except for heavy-duty vehicles equipped with the Caterpillar 3126E engine, the use of a supplemental coolant additive (SCA) such as Motorcraft Heavy-Duty Cooling System Additive, service part number FW-16, is not required in conjunction with this coolant. Testing is currently underway to determine the backward compatibility of the Motorcraft Premium Gold Engine Coolant in vehicles equipped with the green-colored Motorcraft Premium Engine Coolant, service part numbers VC-4-A, VC-4-B, and VC-5. Until the final test results are available, vehicles should ONLY be serviced with type of coolant with which they were originally equipped. Please note that Motorcraft Premium Gold Engine Coolant is not compatible with any orange-colored, extended-life engine coolants such as Motorcraft Specialty Orange Engine Coolant, service part numbers VC-2 and VC-3. DO NOT MIX COOLANT TYPES. USE ONLY THE TYPE OF COOLANT WITH WHICH THE VEHICLE WAS EQUIPPED. Failure to follow these guidelines may result in degradation of corrosion protection and potential engine damage. Coolant Discoloration: The current Motorcraft Cooling System Stop Leak Pellets, service part number VC-6, used in both Production and Service, cause the yellow-colored Motorcraft Premium Gold Engine Coolant to change color ranging from a light golden brown to dark brown, depending upon the amount of pellet Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - Premium Gold Coolant Service Info > Page 2020 material in the coolant reservoir. This discoloration does not adversely affect the coolant or the vehicle's cooling system components. No repairs are required for this condition. To avoid confusion with regard to coolant contamination, a new formulation of stop leak pellets will be implemented in Production and Service in the near future. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 02-17-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - Premium Gold Coolant Service Info > Page 2021 Coolant: Technical Service Bulletins Engine Coolant - Propylene Glycol Recommendations Article No. 01-23-6 11/26/01 ^ ENGINE COOLANT - PROPYLENE GLYCOL - FORD MOTOR COMPANY POSITION ON ENGINE COOLANTS MADE FROM PROPYLENE GLYCOL ^ ENGINE COOLANT - PROPYLENE GLYCOL-BASED - FORD MOTOR COMPANY POSITION ON PROPYLENE GLYCOL-BASED ENGINE COOLANTS FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2002 FOCUS 2002 THUNDERBIRD 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT 2000-2002 F-650, F-750 LINCOLN: 1989-1992 MARK VII 1989-2002 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1989-1994 TOPAZ 1989-1997 COUGAR 1989-2002 GRAND MARQUIS, SABLE 1991-1994 CAPRI 1991-1999 TRACER 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER MERKUR: 1989 SCORPIO, XR4TI This article is being republished in its entirety to update the model year coverage. ISSUE This TSB article describes Ford Motor Company's position on the use of propylene glycol-based engine coolants. ACTION Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - Premium Gold Coolant Service Info > Page 2022 Ford Motor Company does not recommend nor endorse the use of engine coolants made with propylene glycol in Ford vehicles. Ford Motor Company currently recommends the use of ethylene glycol-based engine coolants. Published information suggests that engine coolants made with propylene glycol may provide engine cooling performance equivalent to engine coolants made with ethylene glycol. However, different brands of engine coolant provide varying corrosion protection for the cooling system. Ford does not have performance data for the multitude of engine coolants available in the aftermarket and therefore cannot recommend the use of any coolant except those sold by Ford Customer Service Division. Consult the vehicle's Owner's Guide to determine the appropriate Ford Customer Service Division coolant for the vehicle. Furthermore, claims of toxicological and environmental advantages of propylene glycol over ethylene glycol may be misleading. When significant new information is developed, Ford will review this policy. Ford Motor Company specifications recommend that vehicles be maintained using certain ethylene glycol-based engine coolants. Those specifications do not refer to engine coolants made with propylene glycol. Although the Ford New Vehicle Limited Warranty is not automatically voided upon the use of a coolant made with propylene glycol, if such use results in damage to the vehicle or its components, the cost of repairing the damage would not be covered by the Ford New Vehicle Limited Warranty. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-16-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Cooling System Capacity System Capacity ........................................................................................ ........................................................................................ 13.2 liters (14.0 quarts) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 2025 Coolant: Fluid Type Specifications Motorcraft Premium Engine Coolant ........................................................................................................................... VC-4-A (in Oregon VC-5, in Canada CXC-10) or equivalent (green color) Motorcraft Premium Gold Engine Coolant ..................................................................................................................................................... VC-7-A (in Oregon VC-7-B) or equivalent (yellow color) NOTE: Use the same type of coolant that was drained from the cooling system. Do not mix coolant types. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Differential Fluid - A/T > Component Information > Specifications > Capacity Specifications Differential Fluid - A/T: Capacity Specifications "Information not provided by the manufacturer" Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Differential Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 2030 Differential Fluid - A/T: Fluid Type Specifications "Information not provided by the manufacturer" Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Differential Fluid - M/T > Component Information > Specifications Differential Fluid - M/T: Specifications "Information not supplied by the manufacturer" Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - 5R55W Correct Fluid Checking Procedure Technical Service Bulletin # 01-7-6 Date: 010420 A/T - 5R55W Correct Fluid Checking Procedure Article No. 01-7-6 04/20/01 TRANSMISSION - 5R55W - CORRECT TRANSMISSION FLUID CHECKING PROCEDURE FORD: 2002 EXPLORER MERCURY: 2002 MOUNTAINEER ISSUE Improper checking of the transmission fluid level may result in the misdiagnosis of transmission concerns. ACTION To properly check the transmission fluid level, use the procedures as found in the current CD-ROM, Workshop Manual, STARS Broadcast, and as listed in this TSB. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 504000, 510000 Service Procedure SPECIAL SERVICE TOOL(S) 205-025 - Gauge, Drive Pinion Angle (T68P-4602-A) (Figure 1). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - 5R55W Correct Fluid Checking Procedure > Page 2038 418-F224 - Worldwide Diagnostic System (WDS) - New Generation Star (NGS) Tester 418-F205 or equivalent scan tool (Figure 2). 303-D104 - Oil Suction Gun (D94T-9000-A) (Figure 3). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - 5R55W Correct Fluid Checking Procedure > Page 2039 307-437 - Adapter, Fluid Level and Fill Plug (Figure 4). NOTE LEFT SIDE OF CASE IS SHOWN. FLUID LEVEL CHECK (Fluid Fill Reference Figure 5) 1. Using the scan tool (WDS), monitor the transmission fluid temperature (TFT) using PID: TFT. 2. Start the vehicle. NOTE ENGINE IDLE SPEED IS APPROXIMATELY 650 RPM. 3. Run the engine until the transmission fluid temperature is between 27°C-49°C (80°F-120° F). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - 5R55W Correct Fluid Checking Procedure > Page 2040 4. Move the range selector lever slowly through each gear, stopping in each position and allowing the transmission to engage (Figure 6). 5. Place the range selector lever in the Park position. 6. Raise and support the vehicle with the engine running. For additional information, refer to Workshop Manual Section 100-02. 7. If needed, use special tool 205-025 to set the vehicle as close to level as possible (Figure 7). 8. Place a suitable drain pan under the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - 5R55W Correct Fluid Checking Procedure > Page 2041 9. With the transmission range selector lever in the Park position, hold the larger drain plug with a wrench and remove the small (center) fluid level indicating plug using a 3/16 inch Allen key (Figure 8). 10. Allow the fluid to drain. Wait approximately 1 minute. When the fluid comes out as a thin stream or a drip, the fluid is at the correct level (Figure 9). 11. If no fluid comes out of the hole, fluid will need to be added. Continue with this procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - 5R55W Correct Fluid Checking Procedure > Page 2042 12. Install special tool 307-437 into the pan (Figure 10). 13. Using special tool 303-D104, extract approximately 0.47 L (1 pint) of clean automatic transmission fluid from a suitable container (Figure 11). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - 5R55W Correct Fluid Checking Procedure > Page 2043 14. Using the special tools, fill the transmission with clean automatic transmission fluid (Figure 12). 15. Remove special tool 303-D104. 16. Allow the fluid to drain. Wait approximately 1 minute. When the fluid comes out as a thin stream or drip, the fluid is at the correct level. If no fluid drains from the plug, keep adding fluid in 0.24 L (1/2 pint) increments until the fluid starts to drain from the plug (Figure 13). 17. Remove the special tool from the pan (Figure 10). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - 5R55W Correct Fluid Checking Procedure > Page 2044 18. Reinstall the small (center) fluid level indicating plug using a 3/16 inch Allen key. Torque to 10 N.m (89 lb-in) (Figure 14). 19. Remove special tool 205-025 level gauge (if used). 20. Lower the vehicle. 21. Remove the WDS. 22. Check the operation of the transmission by moving the range selector lever slowly through each gear, stopping in each position and allowing the transmission to engage. 23. Raise and support the vehicle with the engine running and check for any leaks. For additional information, refer to Workshop Manual Section 100-02. 24. Lower the vehicle and shut off the engine. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid .............................................................................................................................. ...................................................... 9.5L (10.0 quarts) Note: Approximate dry capacity includes cooler and tubes. Fluid level procedures should be used to determine actual fluid requirements and fluid specification. DO NOT OVERFILL. If it is necessary to add or change fluid, use only fluid, which has been certified by the supplier as meeting the Ford Motor Company specification shown. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 2047 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ..................................................................................................................................................... ............................................ MERCON V XT-5-QM Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition Fluid - A/T: Service and Repair A/T Fluid Level Check and Condition With Dip Stick Check Fluid Level and Condition CAUTION: The vehicle should not be driven if the fluid level indicator shows the fluid below the Do Not Drive mark or internal failure could result. NOTE: Automatic transmission fluid expands when warmed. To obtain an accurate fluid level check, drive the vehicle until warmed, approximately 30 km (18.75 miles). If the vehicle has been operated for an extended period at high speeds, in city traffic, during hot weather or while pulling a trailer. the vehicle should be turned off for about 30 minutes to allow the fluid to cool before checking. NOTE: The transmission fluid level should be checked at normal operating temperatures, 66 - 77 °C (150 - 170 °F), on a level surface. The normal operating temperature can be reached after approximately 32 km (20 miles) of driving. However, you can check the fluid level without driving if the outside temperature is above 10 °C (50 °F). When the vehicle has not been driven, and the outside is above 10 °C (50 °F), the fluid level should be between the holes on the indicator. If the transmission fluid is to be checked when the fluid is at room temperature, the fluid level indicator could indicate that fluid should be added if the indicator is misread. If fluid is added at this time, an overfill condition could result when the vehicle reaches operating temperature of 66 - 77 °C (150 170 °F). 1. Drive the vehicle 30 km (18.75 miles) or until the vehicle reaches normal operating temperatures. 2. Park the vehicle on a level surface and apply the parking brake. 3. With the parking brake applied and your foot on the brake pedal, start the engine and move the range selector lever through all the gear ranges. Allow sufficient time for each gear to engage. 4. Place the range selector lever in (P) park and leave the engine running. 5. Remove the fluid level indicator and wipe it clean with a lint free cloth. 6. Install the fluid level indicator until it is fully seated into the filler tube. 7. Remove the fluid level indicator and inspect the fluid level. The fluid level should be in the designated area for normal and room temperature. High Fluid Level Fluid levels above the safe range may result in transmission failure. An overfill condition of transmission fluid may cause shift or engagement concerns and possible damage. High fluid levels can be caused by an overheating condition. A fluid level that is too high may cause the fluid to become aerated due to the churning action of the rotating internal parts. This will cause erratic control pressure, foaming, loss of fluid from the vent tube and possible transmission malfunction and/or damage. If an overfill reading is indicated drain and refill the transmission. Low Fluid Level DO NOT DRIVE the vehicle if the fluid level is below the hole at the bottom of the fluid level indicator or not on the fluid level indicator, and the outside temperatures are above 10 °C (50 °F). A low fluid level could result in poor transmission engagement, slipping, malfunction and/or damage. This could also indicate a leak in one of the transmission seals or gaskets. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition > Page 2050 Adding Fluid CAUTION: The use of any other type of transmission fluid than specified could result in transmission malfunction and/or damage. An overfill condition of transmission fluid may cause shift or engagement concerns and possible damage. Before adding fluid be sure that the correct type is being used. If fluid needs to be added, add fluid in 0.25 L (1/2 pint) increments through the filler tube. Do not overfill the fluid. Fluid Condition Check 1. Check the fluid level. 2. Observe the color and the odor. The color under normal circumstances should be dark reddish, not brown or black. 3. Hold the fluid level indicator over a white facial tissue and allow the fluid to drip onto the facial tissue and examine the stain. 4. If evidence of solid material is found, the transmission fluid pan should be removed for further inspection. 5. If the stain is a foamy pink color, this may indicate coolant in the transmission. The engine cooling system should also be inspected at this time. 6. If fluid contamination or transmission failure is confirmed by the sediment in the bottom of the transmission fluid pan, the transmission must be disassembled and completely cleaned. This includes the torque converter and cooler lines. 7. Carry out diagnostic checks and adjustments. Without Dip Stick Fluid Pan, Gasket and Filter Removal 1. Raise and support the vehicle. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. If equipped, loosen the nut and position the heat shield out of the way. 2. Place a drain pan under the transmission fluid pan. 3. Drain transmission fluid. - Disconnect the LH three-way catalytic converter heated oxygen sensor connectors and remove the converter. - Remove all the transmission fluid pan bolts except for two in the front. Loosen the two front transmission fluid pan screws. Pry the rear of the transmission fluid pan down and allow fluid to drain. After fluid is drained, remove the front two transmission fluid pan screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition > Page 2051 4. Remove the transmission fluid pan. 1. Remove the transmission fluid pan. 2. Remove and discard the transmission fluid pan gasket. 5. Remove and discard the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 6. Clean and inspect the transmission fluid pan and magnet. Clean all mating surfaces. 7. Flush the transmission fluid cooler and transmission fluid cooler lines. Installation 1. CAUTION: Lubricate fluid filter O-rings with MERCON(R) V Automatic Transmission Fluid XT-5-QM meeting Ford specification MERCON (R) V or they may be damaged. Lube and install new O-rings onto the transmission fluid filter. Install a new transmission fluid filter. ^ Position transmission fluid filter on the main control valve body. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition > Page 2052 2. CAUTION: Make sure wire harness is not pinched under filter. Install transmission fluid filter screw. 3. Position the oil pan magnet in the transmission fluid pan. 4. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Install and align the transmission fluid pan. ^ Loosely install the transmission fluid pan screws. 5. Tighten the transmission fluid pan screws. ^ Use a crisscross sequence to tighten the transmission fluid pan screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition > Page 2053 6. If equipped, position the servo heat shield over the servos and clip it to the pan rail. 7. Lower the vehicle. 8. NOTE: When filling a dry transmission and converter, start with a minimum of 3.7 liters (4 quarts). Fill transmission to the correct fluid level and check for correct transmission operation. ^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM meeting Ford specification MERCON(R) V. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition > Page 2054 Fluid - A/T: Service and Repair Transmission Fluid Drain and Refill With Dip Stick Transmission Fluid Level Check NOTE: This drain and fill procedure is referenced from TSB # 02-20-3 and applies to 5R55N, 5R55S, and 5R55W Automatic Transmissions. Part 2 Of 2 Special Tool(s) Fluid Fill Reference Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition > Page 2055 NOTE: Left side of case is shown. 1. Using the scan tool (WDS), monitor the Transmission Fluid Temperature (TFT) using PID TFT. 2. Start the vehicle. 3. NOTE: Engine idle speed is approximately 650 rpm. While proceeding with this procedure, run the engine until the transmission fluid temperature is between 27°C - 49°C (80°F - 120°F). 4. Move the range selector lever slowly through each gear, stopping in each position and allowing the transmission to engage. 5. Place the range selector lever in the PARK position. 6. With the engine running, position the vehicle on a hoist and set it as close to level as possible. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition > Page 2056 7. Hold the larger drain plug with a wrench and remove the small (center) fluid level indicating plug using a 3/16-inch Allen key. 8. Install the special tool into the pan. 9. NOTE: Prior to filling the special tool with clean transmission fluid, make sure that the canister is clean. Fill the special tool with clean automatic transmission fluid. 10. Hang the special tool under the vehicle. Position it upright and close to the transmission. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition > Page 2057 11. Connect the special tools. ^ Connect the open end of the fluid hose from the Fluid Transporter/Evacuator/Injector to the Fluid Level and Fill Plug Adapter at the bottom of the transmission fluid pan. 12. Apply a maximum of 206.85 kPa (30 psi) to the open end of the vacuum/pressure hose from the special tool. Fluid will immediately start flowing out of the special tool into the transmission fluid pan. 13. Add one pint of transmission fluid into the fluid pan. Stop the process by releasing the air pressure and removing the air nozzle from the end of the hose. 14. Inspect the fluid level in the special tool. If the fluid drains back into the canister, the transmission is full. If no fluid drains back, more fluid will need to be added. Repeat steps 12 and 13. 15. Once the transmission is full, place a hand vacuum pump on the open end of the vacuum/pressure hose of the special tool and apply vacuum to the system. This will pull out any extra fluid trapped in the system and direct it into the corner 16. Allow the fluid to drain. Make sure that the fluid temperature is between 27°C - 49°C (80°F 120°F). When the fluid comes out as a thin stream or drip, the fluid is at the correct level. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition > Page 2058 17. Reinstall the small (center) fluid level indicating plug using a 3/16 inch Allen key. 18. Check the operation of the transmission by moving the range selector lever slowly through each gear, stopping in each position and allowing the transmission to engage. Without Dip Stick Fluid Pan, Gasket and Filter Removal 1. Raise and support the vehicle. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. If equipped, loosen the nut and position the heat shield out of the way. 2. Place a drain pan under the transmission fluid pan. 3. Drain transmission fluid. - Disconnect the LH three-way catalytic converter heated oxygen sensor connectors and remove the converter. - Remove all the transmission fluid pan bolts except for two in the front. Loosen the two front transmission fluid pan screws. Pry the rear of the transmission fluid pan down and allow fluid to drain. After fluid is drained, remove the front two transmission fluid pan screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition > Page 2059 4. Remove the transmission fluid pan. 1. Remove the transmission fluid pan. 2. Remove and discard the transmission fluid pan gasket. 5. Remove and discard the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 6. Clean and inspect the transmission fluid pan and magnet. Clean all mating surfaces. 7. Flush the transmission fluid cooler and transmission fluid cooler lines. Installation 1. CAUTION: Lubricate fluid filter O-rings with MERCON(R) V Automatic Transmission Fluid XT-5-QM meeting Ford specification MERCON (R) V or they may be damaged. Lube and install new O-rings onto the transmission fluid filter. Install a new transmission fluid filter. ^ Position transmission fluid filter on the main control valve body. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition > Page 2060 2. CAUTION: Make sure wire harness is not pinched under filter. Install transmission fluid filter screw. 3. Position the oil pan magnet in the transmission fluid pan. 4. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Install and align the transmission fluid pan. ^ Loosely install the transmission fluid pan screws. 5. Tighten the transmission fluid pan screws. ^ Use a crisscross sequence to tighten the transmission fluid pan screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition > Page 2061 6. If equipped, position the servo heat shield over the servos and clip it to the pan rail. 7. Lower the vehicle. 8. NOTE: When filling a dry transmission and converter, start with a minimum of 3.7 liters (4 quarts). Fill transmission to the correct fluid level and check for correct transmission operation. ^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM meeting Ford specification MERCON(R) V. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition > Page 2062 Fluid - A/T: Service and Repair Vehicles Not Equipped With Torque Converter Drain Plug Transmission Fluid Drain and Refill- Vehicles Not Equipped With Torque Converter Drain Plug Draining CAUTION: Use only clean automatic transmission fluid. Do not use any supplemental transmission fluid additives, treatments or cleaning agents. The use of these materials can affect the operation of the transmission, resulting in internal component failure. 1. With the vehicle in PARK, position on a hoist. 2. NOTE: If equipped, the transmission servo heat shield must be unclipped from the fluid pan rail and positioned aside for fluid pan removal. If equipped, loosen the nut and position the heat shield aside. 3. Place a drain pan under the transmission fluid pan. 4. Drain the transmission fluid. ^ Remove all the transmission fluid pan bolts except for two in the front. Loosen the two front transmission fluid pan screws. Pry the rear of the transmission fluid pan down and allow the fluid to drain. After the fluid is drained, remove the front two transmission fluid pan screws. 5. Remove the transmission fluid pan. 1. Remove the transmission fluid pan. 2. Remove and discard the transmission fluid pan gasket. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition > Page 2063 6. Clean and inspect the transmission fluid pan and magnet. Clean all mating surfaces. Refill 1. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Install and align the transmission fluid pan ^ Loosely install the transmission fluid pan screws. 2. Tighten the transmission fluid pan screws. ^ Tighten the transmission fluid pan screws in a crisscross sequence. 3. If equipped, position the servo heat shield over the servos and clip it to the pan rail. 4. Lower the vehicle. 5. NOTE: When filling a dry transmission and converter, start with a minimum of 3.7 liters (4 quarts). With the engine running and the transmission at normal operating temperature 66-77°C (150-170°F), check and adjust the transmission fluid level and check for any leaks. If fluid is needed, add fluid in increments of 0.24 liter (0.5 pint) until the correct level is achieved (fluid should be in the Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition > Page 2064 cross-hatched area of the fluid level indicator). 6. Apply the park brake, and start the engine. 7. Move the range selector lever through all the gears. 8. Check the transmission fluid level. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition > Page 2065 Fluid - A/T: Service and Repair Automated Equipment Transmission Fluid Drain and Refill-Automated Equipment Special Tool(s) Draining CAUTION: Use only clean automatic transmission fluid. Do not use any supplemental transmission fluid additives, treatments or cleaning agents. The use of these materials can affect the operation of the transmission, resulting in internal component failure. CAUTION: Always refer to the instructions supplied with the flush and fill machine. NOTE: This is a new procedure for draining and adding transmission fluid using a suitable transmission flush and fill machine. 1. With the vehicle in PARK, position on a hoist. 2. Use a suitable flush and fill machine to change the fluid. 3. When connecting the flush and fill machine, connect the machine to the fluid cooler tube after the fluid cooler on the cooler return tube. This will help remove any foreign material trapped in the fluid coolers. 4. Carry out the fluid exchange process. Refill 1. Use only clean automatic transmission fluid. 2. Once the fluid exchange has been completed, disconnect the flush and fill machine. Reconnect any disconnected fluid cooler tubes. 3. Lower the vehicle. 4. With the engine running and the transmission at normal operating temperature 66-77°C (150-170°F), check and adjust the transmission fluid level and check for any leaks. If fluid is needed, add fluid in increments of 0.24 liter (0.5 pint) until the correct level is achieved (fluid should be in the cross-hatched area of the fluid level indicator). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition > Page 2066 Fluid - A/T: Service and Repair Check Fluid Level and Condition Check Fluid Level and Condition CAUTION: The vehicle should not be driven if the fluid level indicator shows the fluid below the Do Not Drive mark or internal failure could result. NOTE: Automatic transmission fluid expands when warmed. To obtain an accurate fluid level check, drive the vehicle until warmed, approximately 30 km (18.75 miles). If the vehicle has been operated for an extended period at high speeds, in city traffic, during hot weather or while pulling a trailer. the vehicle should be turned off for about 30 minutes to allow the fluid to cool before checking. NOTE: The transmission fluid level should be checked at normal operating temperatures, 66 - 77 °C (150 - 170 °F), on a level surface. The normal operating temperature can be reached after approximately 32 km (20 miles) of driving. However, you can check the fluid level without driving if the outside temperature is above 10 °C (50 °F). When the vehicle has not been driven, and the outside is above 10 °C (50 °F), the fluid level should be between the holes on the indicator. If the transmission fluid is to be checked when the fluid is at room temperature, the fluid level indicator could indicate that fluid should be added if the indicator is misread. If fluid is added at this time, an overfill condition could result when the vehicle reaches operating temperature of 66 - 77 °C (150 170 °F). 1. Drive the vehicle 30 km (18.75 miles) or until the vehicle reaches normal operating temperatures. 2. Park the vehicle on a level surface and apply the parking brake. 3. With the parking brake applied and your foot on the brake pedal, start the engine and move the range selector lever through all the gear ranges. Allow sufficient time for each gear to engage. 4. Place the range selector lever in (P) park and leave the engine running. 5. Remove the fluid level indicator and wipe it clean with a lint free cloth. 6. Install the fluid level indicator until it is fully seated into the filler tube. 7. Remove the fluid level indicator and inspect the fluid level. The fluid level should be in the designated area for normal and room temperature. High Fluid Level Fluid levels above the safe range may result in transmission failure. An overfill condition of transmission fluid may cause shift or engagement concerns and possible damage. High fluid levels can be caused by an overheating condition. A fluid level that is too high may cause the fluid to become aerated due to the churning action of the rotating internal parts. This will cause erratic control pressure, foaming, loss of fluid from the vent tube and possible transmission malfunction and/or damage. If an overfill reading is indicated drain and refill the transmission. Low Fluid Level DO NOT DRIVE the vehicle if the fluid level is below the hole at the bottom of the fluid level indicator or not on the fluid level indicator, and the outside temperatures are above 10 °C (50 °F). A low fluid level could result in poor transmission engagement, slipping, malfunction and/or damage. This could also indicate a leak in one of the transmission seals or gaskets. Adding Fluid Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition > Page 2067 CAUTION: The use of any other type of transmission fluid than specified could result in transmission malfunction and/or damage. An overfill condition of transmission fluid may cause shift or engagement concerns and possible damage. Before adding fluid be sure that the correct type is being used. If fluid needs to be added, add fluid in 0.25 L (1/2 pint) increments through the filler tube. Do not overfill the fluid. Fluid Condition Check 1. Check the fluid level. 2. Observe the color and the odor. The color under normal circumstances should be dark reddish, not brown or black. 3. Hold the fluid level indicator over a white facial tissue and allow the fluid to drip onto the facial tissue and examine the stain. 4. If evidence of solid material is found, the transmission fluid pan should be removed for further inspection. 5. If the stain is a foamy pink color, this may indicate coolant in the transmission. The engine cooling system should also be inspected at this time. 6. If fluid contamination or transmission failure is confirmed by the sediment in the bottom of the transmission fluid pan, the transmission must be disassembled and completely cleaned. This includes the torque converter and cooler lines. 7. Carry out diagnostic checks and adjustments. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > M/T - Mercon(R) V ATF Usage Information Fluid - M/T: Technical Service Bulletins M/T - Mercon(R) V ATF Usage Information TSB 06-26-1 01/08/07 MERCON ATF IS BEING REPLACED BY MERCON V AS A SERVICE FLUID FOR SOME MANUAL TRANSMISSIONS FORD: 1981-2003 Escort 1984-1995 Thunderbird 1985-2007 Mustang 1985-1996 Bronco 1985-2007 Ranger 1986-1997 Aerostar 1991-2004 Explorer 1995-2007 F-150 1996-2007 F-Super Duty 2001-2003 Explorer Sport Trac, Explorer Sport LINCOLN: 2001-2002 Lincoln LS MERCURY: 1984-1995 Cougar 1987-1999 Tracer ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as the service fluid for manual transmissions originally requiring MERCON(R). ACTION Beginning immediately all manual transmission applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will continue until remaining inventory has been depleted. SERVICE PROCEDURE Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > M/T - Mercon(R) V ATF Usage Information > Page 2072 Service manual transmissions requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON/MERCON(R) V. For proper fluid application on current and past model manual transmissions refer to the fluid usage chart. (Figure 1) WARNING FULL SYNTHETIC MANUAL TRANSMISSION FLUID (XT-M5-QS), SAE 75W-90 API GL-4 GEAR OIL (XY-75W90-QGL) AND SAE 75W-90 PREMIUM SYNTHETIC TRANSAXLE LUBRICANT (XT-75W90-QGT) ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS RECOMMENDING THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > M/T - Mercon(R) V ATF Usage Information > Page 2073 Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Manual Transmission Capacity ............................................................................................................................................... ..................................................................... 5.1 Pints Note: Service refill capacity is determined by filling the transmission to the bottom of the filler hole with the vehicle on a level surface. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 2076 Fluid - M/T: Fluid Type Specifications Manual Transmission Fluid .................................................................................................................. ............................................................. Mercon ATF Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Differential Oil Capacity Front Axle ............................................................................................................................................ ......................................................................... 1.5L Rear Axle Conventional Axle ............................................................................................................... ................................................................. 2.60 liters (5.5 pints) Trac-Lock ......................................... ................................................................................................................................................... 2.5 liters (5.25 pints) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 2081 Fluid - Differential: Fluid Type Specifications Differential Fluid Type Rear Axle Type .......................................................................................................................... SAE 80W-90 Premium Rear Axle Lubricant (conventional rear axles) Type ................................................................................................................................ SAE 75W-140 High Performance Rear Axle (Traction-Lok rear ) Front Axle Type ................................................................................................................................... ............................... SAE 80W-90 Premium Rear Axle Lubricant Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter............................................................................................................................................. ............................................................. 4.7L (5.0 Qt) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 2086 Engine Oil: Fluid Type Specifications Engine Oil ...................................................................................................................................... Super Premium SAE 5W30 Motor Oil XO-5W30-QSP Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage Power Steering Fluid: Technical Service Bulletins Steering - Mercon V(R) Fluid Usage TSB 07-1-7 01/22/07 MERCON(R) ATF REPLACED BY MERCON(R) V AS A SERVICE FLUID FOR SOME POWER STEERING SYSTEMS FORD: 1996-1997 Thunderbird 1996-2007 Crown Victoria, Mustang, Taurus 1998-2003 Escort 2000-2007 Focus 2002-2005 Thunderbird 2005-2006 Ford GT 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1996-1997 Aerostar 1996-2007 E-Series, Explorer, Ranger 1997-2004 F-53 Motorhome Chassis 1997-2007 Expedition, F-150, F-Super Duty 1998-2003 Windstar 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2007 Escape 2004-2007 Freestar 2005-2007 Escape Hybrid 1996-1997 Cargo 1996-1998 L-Series 1996-1999 F- B-Series 2000-2007 F-650, F-750 2006-2007 Low Cab Forward LINCOLN: 1996-1998 Mark VIII 1996-1999 Continental 1996-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX MERCURY: 1996-1997 Cougar 1996-2005 Sable 1996-2007 Grand Marquis 1999-2002 Cougar 2003-2004 Marauder 2005-2007 Montego 2006-2007 Milan 1997-2007 Mountaineer 1998-2002 Villager 2004-2007 Monterey 2005-2007 Mariner Hybrid, Mariner ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid for power steering systems originally requiring MERCON(R). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage > Page 2091 ACTION Beginning immediately all power steering applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will continue until remaining inventory has been depleted. SERVICE PROCEDURE Service power steering Systems requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. CAUTION APPLICATIONS RECOMMENDING TYPE F AUTOMATIC TRANSMISSION AND POWER STEERING FLUID MUST CONTINUE TO USE THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 2092 Power Steering Fluid: Specifications MERCON Multi-Purpose (ATF) Transmission Fluid XT-2-QDX MERCON or equivalent meeting Ford Specification MERCON. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Capacity 0.85 kg (30 oz) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 2097 Refrigerant: Fluid Type Specifications Refrigerant Fluid Type Refrigerant Fluid Type R-134a Refrigerant YN-19 WSH-M17B19-A Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service Precautions > Environmental Impact Information Refrigerant: Environmental Impact Information The Ozone Layer A thin layer of ozone molecules, located 10 to 30 miles above the earth, form a protective cover by absorbing a portion of the ultraviolet (UV) radiation emitted from the Sun. Ozone Depletion Scientific research performed over the past 15 years links the release of chlorofluorocarbons (CFC)s, also know by the trade name Freon) into the atmosphere to ozone depletion. When CFCs are released into the atmosphere, they eventually reach the ozone layer located in the stratosphere where they react with and destroy ozone molecules. Harmful Effects Ozone depletion and the corresponding increase in UV radiation has been shown to lead to higher incidents of cancer as well as global warming. When viewed from a global perspective, ozone depletion holds an enormous potential for damage. Upper Level Vs. Ground Level Ozone Confusion often arises when we hear about the necessity of the ozone layer and ground level ozone. The ozone layer existing high above the earth is beneficial but the same compound, when located at ground level, is harmful to humans, animals, crops and vegetation. Ground level ozone is a component of smog and forms when hydrocarbons (HC) react with nitrogen oxides (NOx) in the presence of sunlight and heat. Montreal Protocol In response to the growing body of evidence demonstrating the detrimental effects of (CFC)s, 24 countries and the European community met in Montreal, Canada, in 1987 to establish standards for the control of (CFC)s. Since that time, a total of 132 countries have become signatories to this agreement leading to an end of production of R12 in December, 1995, in all developed countries. As established by the Montreal Protocol, R12 production in developed countries has ceased. Clean Air Act The United States Congress, acting in response to the Montreal Protocol, banned production of (CFC)s by the year 2000. Congress also amended the Clean Air Act in an effort to control both the production and use of (CFC)s for refrigerant applications including mobile vehicle air conditioning systems. Additional Information Sources For more complete and detailed explanations of the above policies, please refer to: http://www.epa.gov/ozone/ Technician Certification Organizations providing technician refrigerant recovery and recycling certification include: National Institute for Automotive Service Excellence (ASE) 13505 Dulles Technology Drive, Suite 2 Herndon, VA 22071-3421 Phone: (703) 713-3800 Fax: (703) 713-0727 http://www.asecert.org/ International Mobile Air Conditioning Association (IMACA) P.O. Box 9000 Fort Worth, TX 76147-2000 Phone: (817) 732-4600 Fax: (817) 732-9610 http://www.imaca.org/ Mobile Air Conditioning Society (MACS) Worldwide P.O. Box 100 East Greenville, PA 18041 Phone: 215-679-2220 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service Precautions > Environmental Impact Information > Page 2100 Fax: 215-541-4635 http://www.macsw.org/ Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service Precautions > Environmental Impact Information > Page 2101 Refrigerant: Vehicle Damage Warnings CAUTION: - Good ventilation is necessary in the area where electronic A/C leak testing is to be carried out. If the surrounding air is contaminated with refrigerant gas, the leak detector will indicate this gas all the time. Odors from other chemicals such as anti-freeze, diesel fuel, disc brake cleaner, or other cleaning solvents can cause the same problem. A fan, even in a well-ventilated area, is very helpful in removing small traces of contamination from the air that might affect the leak detector. - If contaminated refrigerant is detected, DO NOT recover the refrigerant into R-134a or R-12 recovery/recycling equipment. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Testing and Inspection > Electronic Leak Detection Refrigerant: Testing and Inspection Electronic Leak Detection Refrigerent Leak Detector SPECIAL TOOL(S) CAUTION: Good ventilation is necessary in the area where electronic A/C leak testing is to be carried out. If the surrounding air is contaminated with refrigerant gas, the leak detector will indicate this gas all the time. Odors from other chemicals such as anti-freeze, diesel fuel, disc brake cleaner, or other cleaning solvents can cause the same problem. A fan, even in a well-ventilated area, is very helpful in removing small traces of contamination from the air that might affect the leak detector. 1. Leak test the refrigerant system using the Refrigerant Leak Detector. Follow the instructions included with the leak detector for handling and operation techniques. NOTE: The system pressure should be between 413-551 kPa (60-80 psi) at 24°C (75°F) with the engine off. 2. If a leak is found, discharge and recover the refrigerant. - Repair the system. - Test the system for normal operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Testing and Inspection > Electronic Leak Detection > Page 2104 Refrigerant: Testing and Inspection Tracer Dye Leak Detection 120 Watt 110 Volt UV Lamp 20 Degree Celsius SPECIAL TOOL(S) NOTE: Ford Motor Company vehicles are produced with a permanent leak tracer dye incorporated into the A/C system. The location of leaks can be pinpointed by the bright yellow-green glow of the tracer dye. Since more than one leak can exist, always inspect each component. 1. Check for leaks using a 120 Watt UV spot lamp. - Scan all components, fittings and lines of the A/C system. 2. After the leak is repaired, remove any traces of tracer dye with a general purpose oil solvent. 3. Verify the repair by operating the system for a short time and inspect with the UV spot lamp. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant Discharging and Recovery Procedure Refrigerant: Service and Repair Refrigerant Discharging and Recovery Procedure Special Tool(s) SPECIAL TOOL(S) Refrigerant System Recovery NOTE: Ford Motor Company recommends use of an A/C service center to carry out recovery, evacuation, and charging of the refrigerant system. If an A/C service center is not available, refrigerant system recovery, evacuation, and charging may be accomplished using a separate recovery station, vacuum pump, charging cylinder, and manifold gauge set. 1. Prior to recovering the refrigerant system, you must verify the purity of the refrigerant. 2. Connect an R-134a A/C service center to the low- and high-pressure service gauge port valves. NOTE: Some R-134a service centers require the use of an A/C manifold gauge set. 3. Recover the refrigerant from the system following the operating instructions provided by the equipment manufacturer. 4. Once the service center has recovered the vehicle A/C system refrigerant, close the service center inlet valve (if equipped). Then switch off the power supply. 5. Allow the vehicle A/C system to remain closed for about two minutes. Observe the system vacuum level as shown on the gauge. If the vacuum does not decrease, disconnect the refrigerant center hose(s). 6. If the system vacuum does decrease, repeat Steps 2 through 5 until the vacuum level remains stable for two minutes. 7. Carry out the required repairs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant Discharging and Recovery Procedure > Page 2107 Refrigerant: Service and Repair Identifying Refrigerants Delux A/C Refrigerant Analyzer SPECIAL TOOL(S) 1. Follow the instructions included with the Deluxe Refrigerant Diagnostic Tool to obtain the sample for testing. NOTE: An A/C refrigerant analyzer must be used to identify gas samples taken directly from the refrigeration system or storage containers prior to recovering or charging the refrigerant system. 2. The diagnostic tool will display one of the following: - If the purity level of R-134a or R-12 is 98% or greater by weight, the green "PASS" Light Emitting Diode (LED) will light. The weight concentrations of R-134a, R-12, R-22, hydrocarbons, and air will be displayed on the digital display. - If refrigerants R-134a or R-12 do not meet the 98% purity levels, the red "FAIL" LED will light and a horn will sound alerting the user of potential hazards. The weight concentrations of R-134a, R-12, R-22, and hydrocarbons will be displayed on the digital display. - If hydrocarbon concentrations are 2% or greater by weight, the red "FAIL" LED will light, "Hydrocarbon High" will be displayed on the digital display, and a horn will sound alerting the user of potential hazards. The weight concentrations of R-134a, R-12, R-22, and hydrocarbons will also be displayed on the digital display. 3. The percentage of air contained in the sample will be displayed if the R-134a or R-12 content is 98% or greater. The diagnostic tool eliminates the effect of air when determining the refrigerant sample content because air is not considered a contaminant, although air can affect A/C system performance. When the diagnostic tool has determined that a refrigerant source is pure (R-134a or R-12 is 98% or greater by weight) and air concentration levels are 2% or greater by weight, the diagnostic tool will prompt the user if an air purge is desired. 4. If contaminated refrigerant is detected, repeat the refrigerant identification test to verify that the refrigerant is indeed contaminated. 5. Recover any contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant. CAUTION: If contaminated refrigerant is detected, DO NOT recover the refrigerant into R-134a or R-12 recovery/recycling equipment. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant Discharging and Recovery Procedure > Page 2108 Refrigerant: Service and Repair Handling of Contaminated Refrigerants 1. Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant. - This equipment must only be used to recover contaminated refrigerant to prevent the spread to other vehicles. - If this equipment is not available, contact an A/C repair facility in your area with the correct equipment to carry out this repair. CAUTION: If contaminated refrigerant is detected, DO NOT recover the refrigerant into your recovery/recycling equipment. 2. Determine and correct the cause of the customer's initial concern. 3. The suction accumulator/drier cannot be cleaned and a new suction accumulator/drier must be installed. Remove the suction accumulator/drier. NOTE: Residual refrigerant oil in the suction accumulator/drier must be drained and measured for correct oil system matching. 4. Clean the A/C evaporator core and the A/C condenser core by flushing. 5. Install the new suction accumulator/drier. 6. Correctly oil match the system. 7. Evacuate and charge the system. 8. Dispose of contaminated refrigerant according to all federal, state and local regulations. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant Discharging and Recovery Procedure > Page 2109 Refrigerant: Service and Repair Evacuation and Charging Special Tool(s) SPECIAL TOOL(S) Refrigerant System Evacuation NOTE: Ford Motor Company recommends use of an A/C service center to carry out recovery, evacuation, and charging of the refrigerant system. If an A/C service center is not available, refrigerant system recovery, evacuation, and charging may be accomplished using a separate recovery station, vacuum pump, charging cylinder, and manifold gauge set. 1. Connect an R-134a service center to the low- and high-pressure service gauge port valves. 2. Evacuate the system until the low-pressure gauge reads at least 99.4 kPa (29.5 in-Hg) of vacuum and as close to 101.1 kPa (30 in-Hg) as possible. Continue to operate the vacuum pump for a minimum of 45 minutes. 3. Turn off the vacuum pump. Observe the low-pressure gauge for five minutes to make sure that the system vacuum is held. If vacuum is not held for five minutes, leak test the system, service the leak, and evacuate the system again. Refrigerant System Charging NOTE: Ford Motor Company recommends use of an A/C service center to carry out recovery, evacuation, and charging of the refrigerant system. If an A/C service center is not available, refrigerant system recovery, evacuation, and charging may be accomplished using a separate recovery station, vacuum pump, charging cylinder, and manifold gauge set. 1. Correctly oil match the system to verify that the correct amount of refrigerant oil is present in the system. 2. Charge the system with the specified amounts of refrigerant oil and refrigerant. 3. When no more refrigerant is being drawn into the system, start the engine and select MAX A/C operation. Adjust the blower motor speed to the maximum and allow the remaining refrigerant to be drawn into the system. Continue to add refrigerant into the system until the specified weight of R-134a has been added. Close the charging cylinder valve and allow the system to pull any remaining refrigerant from the hose. When the low-pressure drops to approximately 207 kPa (30 psi), close the charging hose valve. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Page 2110 Refrigerant: Tools and Equipment Refrigerent Leak Detector 120 Watt 110 Volt UV Lamp 20 Degree Celsius Special Tool(s) Delux A/C Refrigerant Analyzer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Capacity 266 ml (9 oz) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 2115 Refrigerant Oil: Fluid Type Specifications Refrigerant Oil Type Refrigerant Oil Type PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) WSH-M1C231-B Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 2116 Refrigerant Oil: Service Precautions CAUTION: During normal A/C operation, oil is circulated through the system with the refrigerant, and a small amount is retained in each component. If certain components of the system are removed for new installation, some of the refrigerant oil will go with the component. To maintain the original total oil charge, it is necessary to compensate for the oil lost by adding oil to the system with the new part. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 2117 Refrigerant Oil: Service and Repair REFRIGERANT OIL ADDITION CAUTION: During normal A/C operation, oil is circulated through the system with the refrigerant, and a small amount is retained in each component. If certain components of the system are removed for new installation, some of the refrigerant oil will go with the component. To maintain the original total oil charge, it is necessary to compensate for the oil lost by adding oil to the system with the new part. 1. Rotate the A/C compressor shaft six to eight revolutions while collecting oil in a clean measuring device. - If the amount of oil drained from the old A/C compressor is between 85-142 ml (3-5 ounces), pour the same amount plus 30 ml (1 ounce) of clean PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) WSH M1C231-B or equivalent into the new A/C compressor. - If the amount of oil that was removed from the old A/C compressor is greater than 142 ml (5 ounces), pour the same amount drained of clean PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent into the new A/C compressor. - If the amount of oil that was removed from the old A/C compressor is less than 85 ml (3 ounces), pour 85 ml (3 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent into the new A/C compressor. NOTE: Service A/C compressors are shipped without compressor oil. 2. For the suction accumulator/drier, drill one 13 mm (0.52 in) hole in the suction accumulator/drier cylinder and drain the oil into a calibrated container. Add a quantity of new oil to match that drained from the old suction accumulator/drier plus 60 ml (2 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent. 3. For the A/C evaporator core, add 89 ml (3 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent to the suction accumulator/drier inlet tube. 4. For the A/C condenser core, add 30 ml (1 ounce) of clean PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent to the A/C condenser core or the suction accumulator/drier inlet tube. 5. Add 60 ml (2 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent to the suction accumulator/drier inlet tube when carrying out each of the following repairs: installation of a new A/C evaporator core orifice - installation of a new A/C compressor pressure relief valve - installation of a new refrigerant line - repair of an O-ring seal leak - repair of a charge port leak 6. Installation of new components that do not require discharge of refrigerant and resulting oil loss, such as the A/C cycling switch and the A/C pressure transducer, do not require additional oil. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding Brake Bleeding: Service and Repair Brake Caliper Bleeding Caliper WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water to induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. 1. NOTE: It is not necessary to do a complete brake system bleed if only the disc brake caliper was disconnected. Place a box end wrench on the disc brake caliper bleeder screw. Attach a rubber drain tube to the disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3. Loosen the disc brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 4. Tighten the disc brake caliper bleeder screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 2122 Brake Bleeding: Service and Repair Brake System Manual Bleeding Manual WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. NOTE: When any part of the hydraulic system has been disconnected for repair or installation of new components, air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 2. NOTE: Disc brake is shown, drum brake is similar. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 3. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 2123 4. NOTE: Disc brake is shown, drum brake is similar. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH rear bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 5. Continue bleeding the system going in order from the LH rear bleeder screw to the RH front bleeder screw ending with the LH front bleeder screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 2124 Brake Bleeding: Service and Repair Brake System Pressure Bleeding Pressure WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water to induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 2. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers of pressure bleeding equipment. Follow the instructions of the manufacturer when installing the adapter. Install the bleeder adapter to the brake master cylinder reservoir, and attach the bleeder tank hose to the fitting on the adapter. 3. NOTE: Disc brake is shown, drum brake is similar. NOTE: Bleed the longest line first. Make sure the bleeder tank contains enough specified brake fluid to complete the bleeding operation. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 4. Open the valve on the bleeder tank. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 2125 5. NOTE: Disc brake is shown, drum brake is similar. Loosen the RH rear bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten the RH rear bleeder screw and remove the rubber hose. 6. Continue bleeding the rear of the system, going in order from the LH rear bleeder screw to the RH front bleeder screw, ending with the LH front bleeder screw. 7. Close the bleeder tank valve. Remove the tank hose from the adapter, and remove the adapter. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 2126 Brake Bleeding: Service and Repair Four Wheel ABS Hydraulic Control Unit (HCU) Four Wheel Anti-Lock Brake System (4WABS) Hydraulic Control Unit (HCU) WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water to induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. NOTE: This procedure only needs to be carried out if a new 4-Wheel Anti-Lock Brake (4WABS) Hydraulic Control Unit (HCU) has been installed. 1. Connect the scan tool DCL cable adapter into the vehicle Data Link Connector (DLC) under the dash, and follow the scan tool instructions for bleeding. 2. Clean all dirt from and remove the brake master cylinder filler cap, and fill the brake master cylinder reservoir with the specified brake fluid. 3. NOTE: Disc brake is shown, drum brake is similar. Connect a clear drain tube to the RH rear bleeder screw and the other end in a container partially filled with recommended brake fluid. 4. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 2127 5. NOTE: Disc brake is shown, drum brake is similar. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 6. Continue bleeding the system, going in order from the LH rear bleeder screw to the RH front bleeder screw, ending with the LH front bleeder screw. 7. Repeat the bleed procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 2128 Brake Bleeding: Service and Repair Master Cylinder Priming - In-Vehicle or Bench Master Cylinder Priming-In-Vehicle or Bench Special Tool(s) WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake component and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or installation, air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. NOTE: When a new brake master cylinder has been installed or the system has been emptied or partially emptied, it must be primed to prevent air from entering the system. 1. For in-vehicle priming, disconnect the brake lines from the brake master cylinder. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 2129 2. For bench priming, mount the brake master cylinder in a vise. 3. Install short brake tubes with the ends bent into the brake master cylinder reservoir. ^ Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A. 4. For a new brake master cylinder, loosen the brake pressure switch. 5. Slowly depress and hold the primary piston or, for in-vehicle driving, have an assistant slowly depress and hold the brake pedal. Tighten the brake pressure switch. 6. Repeat the above three steps until no air bubbles are visible in the expelled fluid. 7. Slowly depress the primary piston or, for in-vehicle priming, have an assistant slowly pump the brake pedal until clear brake fluid flows from both brake tubes with no air bubbles. 8. If necessary, install the brake master cylinder into the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 2130 9. Remove the short brake tubes and install the master cylinder outlet tubes. 10. Loosen a brake outlet tube at the 4WABS Hydraulic Control Unit (HCU). 11. NOTE: Refill the brake master cylinder reservoir as necessary. Have an assistant depress and hold the brake pedal. Tighten the outlet tube fitting at the HCU. 12. Repeat the above three steps until no air bubbles are visible in the expelled brake fluid. 13. Repeat the above four steps for the remaining master cylinder outlet tube. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 2131 14. Connect one end of a flexible tube to the master cylinder bleeder screw. Submerge the other end in a container partially filled with the specified brake fluid. 15. Have an assistant pump and then hold firm pressure on the brake pedal. 16. NOTE: Refill the brake master cylinder reservoir as necessary. Loosen the master cylinder bleeder screw until brake fluid flows out of the drain tube. 17. Tighten the master cylinder bleeder screw. 18. Repeat the above three steps until there are no air bubbles in the expelled brake fluid. 19. Bleed the brake system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Customer Safety Information Air Bag(s) Arming and Disarming: Customer Safety Information WARNING: ^ IF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS BEING SERVICED, THE SYSTEM MUST BE DEACTIVATED AND RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED. ^ THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, TURN THE IGNITION OFF AND DISCONNECT THE BATTERY GROUND CABLE, WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Customer Safety Information > Page 2136 Air Bag(s) Arming and Disarming: Technician Safety Information WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, CAUTIONS, AND NOTES AT THE BEGINNING OF THE DEACTIVATION PROCEDURE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Customer Safety Information > Page 2137 Air Bag(s) Arming and Disarming: Vehicle Damage Warnings CAUTION: ^ Do not handle the passenger air bag module by grabbing the edges of the deployment door. ^ Do not deactivate the side air bag module circuit be removing the side air bag bridge resistor from the side air bag to floor connector. ^ If the side air bag bridge resistor is removed, an open circuit fault will be generated by the Restraints Control Module (RCM). ^ If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Deactivation Procedure Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will This will reduce the risk of injury in the event of an accidental deployment. WARNING: To reduce the risk of personal injury, do not use any memory saver devices. NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood connected. WARNING: To reduce the risk of personal injury, do not use any memory saver devices. NOTE: The air bag warning lamp illuminates when the RGM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2140 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, See: Starting and Charging/Battery 7. Remove the two steering wheel back cover plugs. 8. Remove the driver air bag module retaining bolts. 9. Remove the driver air bag module. 1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2141 10. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector at the top of the steering column. 11. Open the glove compartment door past its stops to access the mounting screws. 12. Remove the two screws. 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Reaching one hand into the glove compartment opening push out on the passenger air bag module and separate it from the instrument panel. Note the wire harness routing for installation. 14. Disconnect the electrical connector and remove the passenger air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2142 15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. Vehicles without seat side air bags 16. CAUTION: Do not deactivate the side air bag module circuit be removing the side air bag bridge resistor from the side air bag to floor connector. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM). If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. Vehicles with seat side air bags and power driver seat 17. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. For additional information, See: Starting and Charging/Battery Vehicles with seat side air bags 18. Move and tilt the front seats to their highest and most forward position. Vehicles with seat side air bags and power driver seat 19. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, See: Starting and Charging/Battery Vehicles with seat side air bags 20. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector. 21. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2143 22. Remove the tie-strap and disconnect the driver seat side air bag electrical connector. 23. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. All vehicles 24. Install the RCM fuse F2.6 (7.5A without rear blower, 15A with rear blower) to the CJB and close the cover. 25. Connect the battery ground cable. For additional See: Starting and Charging/Battery Reactivation Procedure Reactivation All vehicles 1. Turn the ignition switch to OFF. 2. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For additional information, refer to the wiring Diagram Manual. 3. Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, See: Starting and Charging/Battery Vehicles with seat side air bags 4. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2144 5. Connect the driver seat side air bag electrical connector and tie-strap the wire harness. 6. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical connector. 7. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. Vehicles with seat side air bags and power driver seat 8. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. For additional information, See: Starting and Charging/Battery Vehicles with seat side air bags 9. Position the front seats rearward. Vehicles with seat side air bags and power driver seat 10. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, refer to See: Starting and Charging/Battery All vehicles Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2145 11. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. 12. Position the passenger air bag module to the instrument panel (I/P) and connect the electrical connector. 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Position the passenger air bag module into the instrument panel. Route the wire harness as noted in removal. 14. Install the two screws. 15. Close the glove compartment door. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2146 16. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector at the top of the steering column. 17. Position the driver air bag module to the steering wheel. 1. Connect the driver air bag module electrical connector. 2. Position the driver air bag module to the steering wheel. 18. Install the two driver air bag module retaining bolts. 19. Install the two steering wheel back cover plugs. 20. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 21. Turn the ignition switch from OFF to ON. 22. Install the RCM fuse F2.6 (7.5A without rear blower, 15A with rear blower) to the CJB and close the cover. 23. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2147 Connect the battery ground cable. 24. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: -fail to light. -remain lit continuously. -flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. 25. Clear all continuous DTCs from the restraints control module using a scan tool. Seats Removed There are two deactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. WARNING: IF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS BEING SERVICED, THE SYSTEM MUST BE DEACTIVATED AND RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED. THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. NOTE: ^ Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Disconnect the battery ground cable. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the driver air bag module. 4. Attach a Restraint System Diagnostic Tool 418-F088 (105-R0012) to the clockspring side of the driver air bag module connector. 5. Remove the passenger air bag module. 6. Attach a Restraint System Diagnostic Tool 418-F088 (105-R0012) to the vehicle harness side of the passenger air bag connector. 7. If equipped with a front power driver seat, reconnect the battery ground cable. 8. Move and tilt the front seats to their highest and most forward position. 9. If equipped with a front power driver seat, disconnect the battery ground cable. 10. Remove the affected front seat(s). 11. Disconnect the passenger seat side air bag module electrical connector (if necessary) and attach Restraint System Diagnostic Tool 418-133 (40-009) to the vehicle harness side of the passenger seat side air bag module electrical connector. 12. Disconnect the driver seat side air bag module electrical connector (if necessary) and attach Restraint System Diagnostic Tool 418-133 (40-009) to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2148 the vehicle harness side of the driver seat side air bag module electrical connector. 13. Reconnect the battery ground cable. Seats Not Removed There are two deactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. WARNING: IF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS BEING SERVICED, THE SYSTEM MUST BE DEACTIVATED AND RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED. THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. NOTE: ^ Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Disconnect the battery ground cable. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the driver air bag module. 4. Attach a Restraint System Diagnostic Tool 418-F088 (105-R0012) to the clockspring side of the driver air bag module connector. 5. Remove the passenger air bag module. 6. Attach a Restraint System Diagnostic Tool 418-F088 (105-R0012) to the vehicle harness side of the passenger air bag connector. 7. If equipped with seat side air bags and a front power driver seat reconnect the battery ground cable. 8. Move and tilt the front seats to their highest and most forward position. 9. If equipped with seat side air bags and a front power driver seat, disconnect the battery ground cable. 10. If equipped with seat side air bags, disconnect the passenger seat side air bag module electrical connector and attach Restraint System Diagnostic Tool 418-133 (40-009) to the vehicle harness side of the passenger seat side air bag module electrical connector. CAUTION: Vehicles without side air bags, do not deactivate the side air bag module circuit by removing the side air bag bridge resistor from the side air bag floor connector. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM). If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. 11. If equipped with seat side air bags, disconnect the driver seat side air bag module electrical connector and attach Restraint System Diagnostic Tool 418-133 (40-009) to the vehicle harness side of the driver seat side air bag module electrical connector. CAUTION: Vehicles without side air bags, do not deactivate the side air bag module circuit by removing the side air bag bridge resistor from the side air bag floor connector. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2149 If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. 12. Reconnect the battery ground cable. Seats Removed There are two reactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES AND PRETENSIONERS MUST BE RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. 1. Move and tilt the front seats to their highest and most forward position. 2. Disconnect the battery ground cable. 3. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 4. Remove the restraint system diagnostic tool from the driver seat side air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. Remove the restraint system diagnostic tool from the passenger seat side air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 6. Install the affected front seat(s). 7. Connect the driver seat side air bag module electrical connectors. 8. Connect the passenger seat side air bag module electrical connectors. 9. If equipped with a front power driver seat, reconnect the battery ground cable. 10. Move the front seats rearward. 11. If equipped with a front power driver seat, disconnect the battery ground cable. 12. Remove the restraint system diagnostic tool from the passenger air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 13. Install the passenger air bag module. 14. Remove the restraint system diagnostic tool from the clockspring connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 15. Install the driver air bag module. 16. Reconnect the battery ground cable. 17. Prove out the system. Seats Not Removed There are two reactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES AND Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2150 PRETENSIONERS MUST BE RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. 1. If equipped with seat side air bags, move and tilt the front seats to their highest and most forward position. 2. Disconnect the battery ground cable. 3. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 4. If equipped with seat side air bags: 1 Remove the restraint system diagnostic tool from the driver seat side air bag module electrical connector. 2 Remove the restraint system diagnostic tool from the passenger seat side air bag module electrical connector. 3 Connect the driver seat side air bag module electrical connectors. 4 Connect the passenger seat side air bag module electrical connectors. 5 Reconnect the battery ground cable. 6 Move the front seats rearward. 7 Disconnect the battery ground cable. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. Remove the restraint system diagnostic tool from the passenger air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 6. Install the passenger air bag module. 7. Remove the restraint system diagnostic tool from the clockspring connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 8. Install the driver air bag module. 9. Reconnect the battery ground cable. 10. Prove out the system. Procedures For Repair Operations SPECIAL TOOL(S) DEACTIVATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2151 INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the air bag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the seat side air bag (if equipped) and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Remove the retaining screws and position the hood release handle out of the way. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2152 3. Remove the lower steering column opening finish panel. 1 Remove the two retaining screws from the lower steering column opening finish panel. 2 Pull out to release the retaining clips and remove the lower steering column opening finish panel. 4. Remove the bolts and the lower steering column opening finish panel reinforcement. 5. Disconnect the clockspring electrical connector at the base of the steering column. 6. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2153 7. Open the glove compartment door past its stops to access the mounting screws. 8. Remove the two screws. 9. Reaching one hand into the glove compartment opening, push out on the passenger air bag module and separate it from the instrument panel. Note the wire harness routing for installation. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. 10. Disconnect the electrical connector and remove the passenger air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2154 11. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. Vehicles without seat side air bags 12. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the Restraints Control Module (RCM). If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. CAUTION: Do not deactivate the side air bag module circuit be removing the side air bag bridge resistor from the side air bag to floor connector. Vehicles with seat side air bags and power driver seat 13. Connect the battery ground cable. Vehicles with seat side air bags 14. Move and tilt the front seats to their highest and most forward position. Vehicles with seat side air bags and power driver seat 15. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Vehicles with seat side air bags 16. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2155 17. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. 18. Remove the tie-strap and disconnect the driver seat side air bag electrical connector. 19. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. All vehicles 20. Connect the battery ground cable. 21. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). See: Prove Out Procedure 22. Disconnect the battery ground cable and wait at least one minute. REACTIVATION WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, CAUTIONS, AND NOTES AT THE BEGINNING OF THE DEACTIVATION PROCEDURE. Vehicles with seat side air bags Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2156 1. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical connector. NOTE: Make sure the battery ground cable is still disconnected before proceeding with the reactivation portion of this procedure. 2. Connect the driver seat side air bag electrical connector and tie-strap the wire harness. 3. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical connector. 4. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. Vehicles with seat side air bags and power driver seat 5. Connect the battery ground cable. Vehicles with seat side air bags 6. Position the front seats rearward. Vehicles with seat side air bags and power driver seat Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2157 7. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). All vehicles 8. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. 9. Position the passenger air bag module to the Instrument Panel (I/P) and connect the electrical connector. 10. Position the passenger air bag module into the instrument panel. Route the wire harness as noted in removal. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2158 11. In stall the two screws. 12. Close the glove compartment door. 13. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector at the base of the steering column. 14. Connect the clockspring electrical connector at the base of the steering column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2159 15. Position the lower steering column opening finish panel reinforcement and install the bolts. 16. Install the lower steering column opening finish panel. 1 Position the lower steering column opening finish panel to the I/P and push in at the top to seat the retaining clips. 2 Install the screws. 17. Position the hood release handle and install the screws. 18. Connect the battery ground cable. 19. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Prove Out Procedure WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 20. Check the active restraint system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2160 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag modules connected? 3. Is the Restraints Control Module (RCM) connected? 4. Is the vehicle battery connected? Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2161 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure Turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator with the air bag modules or restraint system diagnostic tools installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag Supplemental Restraint System (SRS) fault is present, the air bag indicator will either: ^ fail to light. ^ remain lit continuously. ^ flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the RUN position. This is the time required for the Restraints Control Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Page 2162 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2168 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2169 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2170 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2171 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2172 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2173 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2174 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2175 Fuse: Locations Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2176 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2177 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2178 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2179 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2180 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2181 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2182 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2183 Fuse: Locations Auxiliary Relay Box 1 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2184 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2185 Fuse: Locations Auxiliary Relay Box 2 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2186 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. NOTE: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2189 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number or the component name in one of the the A-Z Component Lists, the Component Location description for that component can easily be found. See: Locations/Component Locations/A-Z Component List Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2190 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2191 the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2192 that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2193 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2194 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2195 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2196 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2197 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2198 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2199 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2200 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2201 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2202 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2203 Systems Overview Wire Color Code Identification Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2204 OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2205 Fuse: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2206 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2207 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2210 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2211 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2212 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2213 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2214 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2215 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2216 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2217 Fuse: Application and ID Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2218 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2219 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2220 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2221 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2222 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2223 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2224 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2225 Fuse: Application and ID Auxiliary Relay Box 1 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2226 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2227 Fuse: Application and ID Auxiliary Relay Box 2 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2228 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse Block: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2233 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2234 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2235 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2236 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2237 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2238 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2239 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2240 Fuse Block: Locations Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2241 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2242 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2243 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2244 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2245 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2246 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2247 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2248 Fuse Block: Locations Auxiliary Relay Box 1 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2249 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2250 Fuse Block: Locations Auxiliary Relay Box 2 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2251 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. NOTE: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2254 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number or the component name in one of the the A-Z Component Lists, the Component Location description for that component can easily be found. See: Locations/Component Locations/A-Z Component List Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2255 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2256 the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2257 that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2258 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2259 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2260 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2261 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2262 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2263 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2264 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2265 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2266 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2267 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2268 Systems Overview Wire Color Code Identification Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2269 OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2270 Fuse Block: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2271 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2272 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse Block: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2275 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2276 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2277 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2278 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2279 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2280 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2281 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2282 Fuse Block: Application and ID Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2283 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2284 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2285 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2286 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2287 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2288 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2289 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2290 Fuse Block: Application and ID Auxiliary Relay Box 1 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2291 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2292 Fuse Block: Application and ID Auxiliary Relay Box 2 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2293 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2298 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2299 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2300 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2301 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2302 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2303 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2304 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2305 Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2306 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2307 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2308 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2309 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2310 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2311 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2312 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2313 Relay Box: Locations Auxiliary Relay Box 1 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2314 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2315 Relay Box: Locations Auxiliary Relay Box 2 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2316 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2319 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2320 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2321 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2322 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2323 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2324 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2325 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2326 Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2327 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2328 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2329 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2330 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2331 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2332 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2333 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2334 Relay Box: Application and ID Auxiliary Relay Box 1 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2335 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2336 Relay Box: Application and ID Auxiliary Relay Box 2 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2337 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation Malfunction Indicator Lamp (MIL) Check Engine, Service Engine Soon Or ISO Standard Engine Symbol The Malfunction Indicator Lamp (MIL) (Figure 15) alerts the driver that the Powertrain Control Module (PCM) has detected an On Board Diagnostic (OBD) II emission-related component or system fault. When this occurs, an OBD II Diagnostic Trouble Code (DTC) will be set. - The MIL is located on the instrument cluster and is labeled CHECK ENGINE, SERVICE ENGINE SOON or ISO standard engine symbol (Figure 16). - Power is supplied to the MIL whenever the ignition switch is in the RUN or START position. - The MIL will remain on in the RUN/START mode as a bulb check during the instrument cluster proveout for approximately 4 seconds. - If the MIL remains on after the bulb check: The PCM illuminates the MIL for an emission related concern and a DTC will be present. - The instrument cluster will illuminate the MIL if the PCM does not send a control message to the instrument cluster. - The PCM is operating in the Hardware Limited Operation Strategy (HLOS). - The MIL circuit is shorted to ground. - If the MIL remains off (during the bulb check); Bulb is damaged. - MIL circuit is open. - To turn off the MIL after a repair, a reset command from the Scan Tool must be sent, or three consecutive drive cycles must be completed without a fault. - For any MIL concern, go to Symptom Charts. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Reading Diagnostic Trouble Codes/Performance Diagnostic Procedures/Quick Test - If the MIL blinks at a steady rate, a severe misfire condition could possibly exist. - If the MIL blinks erratically, an intermittent open B+ to the bulb or an intermittent short to ground in the MIL circuit exist. Also, the PCM can reset while cranking if battery voltage is low. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair Oil Change Reminder Lamp: Service and Repair The manufacturer does NOT show that this vehicle is equipped with an oil change reminder lamp. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation Vehicle Lifting: Description and Operation JACKING WARNING: ^ DO NOT RUN THE ENGINE WHEN JACKING THE VEHICLE. THE WHEELS CONTACTING THE GROUND COULD CAUSE THE VEHICLE TO MOVE. ^ MAKE SURE THE JACK AND JACK STANDS ARE CORRECTLY LOCATED TO PREVENT THE VEHICLE FROM FALLING. ^ A WHEEL CHOCK SHOULD BE USED TO PREVENT THE VEHICLE FROM ROLLING AND FALLING OFF THE JACK. ^ WHEN ONE OF THE REAR WHEELS IS OFF THE GROUND, THE TRANSMISSION ALONE WILL NOT PREVENT THE VEHICLE FROM MOVING OR SLIPPING OFF THE JACK, EVEN IF THE TRANSMISSION IS IN P (PARK) (AUTOMATIC TRANSMISSION) OR REVERSE (MANUAL TRANSMISSION). Jacking Points - Front Jacking Points - Front The front jacking point is a tab that extends from the lower control arm. Jacking Points - Rear The rear jacking points are located on the rear axle tube CAUTION: Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and adjoining differential housing surface can occur if a floor jack or any lifting device is allowed to contact the cover at any point where the cover joins the housing. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 2349 LIFTING Lifting Points - Front 1. The front lifting points are located underneath the number one body mount bracket. CAUTION: ^ Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and adjoining differential housing surface can occur if a floor jack or any lifting device is allowed to contact the cover at any point where the cover joins the housing. ^ Damage to the suspension, fuel tank, exhaust or steering linkage components can occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. Lifting Point - Rear 1. The rear lifting point is the bottom surface of the leaf spring front eye. CAUTION: ^ Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and adjoining differential housing surface can occur if a floor jack or any lifting device is allowed to contact the cover at any point where the cover joins the housing. ^ Damage to the suspension, fuel tank, exhaust or steering linkage components can occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement Technical Service Bulletin # 01B77 Date: 011001 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2358 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2359 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2360 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2361 Attachment I - Administrative Information OASIS OASIS must be used to determine vehicle eligibility. IMPORTANT: When an eligible vehicle is at the dealership for service, OASIS must be contacted to determine if Owner Notification Program 01B77 is open. If 01B77 is listed in OASIS as open, it is important that the vehicle is inspected for eligible tires. If the eligible vehicle is not equipped with 15-, 16-, or 17-inch Firestone Wilderness AT tires a claim must be submitted using labor operation 01B77A to close the program. If an affected vehicle does not have 01B77 open, this may indicate that a refund or tire replacement has already been processed on this vehicle. Some Ford and Lincoln Mercury vehicles not listed in the AFFECTED TIRES AND VEHICLES list may have 15-, 16-, or 17-inch Firestone Wilderness AT tires installed. These vehicles are covered under this program, but will not be active in OASIS. Contact the Special Service Support Center at 1-800-325-5621 to obtain prior approval before performing the repair or issuing a refund. This will insure that a previous repair/refund has not been performed on the vehicle. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII User Manual for claims preparation and submission information. ^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type. ^ Program code 01B77. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2362 ^ Enter the full part number of the replacement tire with the quantity of tires replaced. Tires will be reimbursed at AtW Dealer cost + 25% (wheel weights and valve stems incl.). ^ Use the appropriate labor operation(s) from Attachment II. ^ Freight is reimbursable at actual cost in the miscellaneous expense area of the claim. NOTE: Freight is only reimbursable for rural dealers whose only means of acquiring tires is by having them shipped in via common carrier. Dealers are encouraged to arrange for shipment of 4 or more tires at a time. ^ Dealers can no longer claim tire disposal for ONP 01B77. See the "National Tire Recovery and Recycle Program". You may still claim any applicable local waste tax - enter OTHER in the expense area of the claim with the actual cost. ^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires on the diagnostic code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the space provided in the diagnostic code area, use the technician comment area to complete the data entry. RELATED DAMAGE Vehicle damage caused by a tire related failure is not covered by this program. Refer to the Warranty and Policy Manual for proper claiming procedure for vehicles covered by the Ford Bumper-to-Bumper Tire Warranty (model years 2001 and 2002). All other pre-2001 model year vehicles with alleged tire related vehicle damage should be handled through the Firestone claims process, or by referring the customers to their insurance company. Damage related to replacement of tires should be handled as described in the Warranty and Policy Manual. OWNER REFUND With the increased availability of replacement tires, it will no longer be necessary for customers to pay out-of-pocket expenses for tires. Therefore, refund requests for tires purchased after November 15, 2001 will no longer be granted. Owners will be notified of the refund expiration date and will be directed to a Ford or Mercury dealer They are directed to an authorized retailer only if the Ford or Mercury dealer cannot meet their scheduling needs or tires are not in stock. All Ford and Mercury dealers (AtW and non-AtW dealers) are required to process refunds for customers who purchase tires prior to November 15, 2001. The following rules apply to refunds for tires purchased from August 1, 2001 through November 15, 2001: Refunds will be processed for vehicles listed under "AFFECTED TIRES AND VEHICLES", and for other Ford and Lincoln Mercury vehicles that have 15-. 16-, or 17-inch Wilderness AT tires installed. ^ The customer must provide the original paid receipt (a copy of their paid receipt is acceptable on an exception basis in instances where the owner requires the original for another purpose (e.g. extended tire warranty or purchase rebate). The dealer will attach the receipt to the dealer file copy of the refund claim (see claim instructions below). ^ Dealers will be reimbursed to immediately disable tires returned for a refund (see claiming instructions for refunds and Attachment II for labor operations). ^ The tires must be purchased August 1, 2000 through November 15, 2001 to be eligible for a refund (through October 31, 2001 for 1995 and 1996 F-150 owners). ^ Customers requesting refunds for tire replacement May 22, 2001 through November 15, 2001 must provide either: NOTE: This does not apply to 1995 and 1996 F-150 customers. ^ The Firestone Wilderness AT tires that were replaced. Returned tire(s) are to be disabled by the dealership. Ford will reimburse the dealer to disable (see claim instructions below and use labor operation 01B77G). If tires are brought in for refund with the DOT codes missing dealers should not process the refund. ^ A section of the old tire(s) containing the DOT codes from each of the Firestone Wilderness AT tires that were replaced (To be cut from the Wilderness AT tires that were replaced by the outside repair facility) (use labor operation 01B77L). Dealers should deface (cut in pieces or make code unreadable) the DOT sections of the tire so they cannot be used to obtain another refund. If sections are brought in for refund with the DOT code defaced dealers should not process the refund. NOTE: The DOT Code Identification Guide has been developed to help dealers determine if the DOT sections returned to the dealership are from 15-, 16-, Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2363 or 17-inch Firestone Wilderness AT tires. Use the DOT Code Identification Guide in conjunction with the bulletin section "What if the Vehicle has a Mix of Affected and Non-Affected Tires" to determine how many tires are eligible for refund. NOTE: Ford will allow customers to file for a refund (with or without tires) for tires purchased after May 22 through June 30, 2001 because customers may not have tires to turn in. Customers must provide a paid receipt indicating tire replacement before July 1, 2001 in order to process a refund without tires or DOT sections. Customers who purchase tires after June 30, 2001 must provide tires or DOT sections. Ford will reimburse customers the following amounts: ^ Tires purchased from August 1, 2000 through May 22, 2001, the actual cost as stated on their paid receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes. ^ (1995 and 1996 F-150 vehicle only) Tires purchased from August 1, 2000 through October 31, 2001, the actual cost as stated on their paid receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes. No DOT section required. ^ Tires purchased May 23, 2001 through November 15, 2001, the actual cost as stated on the receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes up to a maximum of $110 per tire for 15 inch, and $130 per tire for 16 and 17 inch tires. ^ Refunds will not be granted for tires purchased after November 15, 2001. Note: If an owner pays for the replacement of their tires after November 15, 2001, the dealer may handle on a case by case basis following the procedure in Attachment II. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2364 CLAIMS PREPARATION FOR REFUNDS (USE THIS PROCEDURE FOR ALL REFUND REQUESTS) NOTE: Tires must be purchased prior to November 15, 2001 ^ Enter claims using DWE. ^ Refer to ACESII User Manual for claims preparation and submission information. ^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type. ^ Program code 01B77. ^ When a customer brings in their old tires and is seeking a refund, use labor operation 01B77G (disable) and 01B77L (refund administration allowance) from Attachment II. ^ If a customer brings in the old DOT codes removed from the old tires - use labor operation 01B77L only. ^ The Miscellaneous Expense Code "ADMIN" will not be accepted under this program. A labor operation 01B77L has been provided to cover administrative costs. ^ Enter REFUND in the miscellaneous area of the claim. ^ Dealers will no longer be able to claim tire disposal for ONP 01B77. See the "National Tire Recovery and Recycle Program" You may still claim any applicable local waste tax - enter OTHER in the expense area of the claim with the actual cost. ^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires in the diagnostic code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the space provided in the diagnostic code area, use the technician comment area to complete the data entry. If the tires were replaced prior to May 23, 2001 (or November 1, 2001 for 1995 and 1996 F150 customers) the DOT may not be available, in this case record the brand, make and size of the tires in the technician comments area of the claim. RENTAL CARS TAP allowances have been increased specifically for this owner notification program. Refer to Don Brunner letter. DOT REGISTRATION OF NEW TIRES Dealers are required to register the DOT number of every tire sold to meet federal tire registration requirements. Ford has established a partnership with CIMS to assist dealers in registering these DOT codes. Information is available on QCDealer.com under CIMS Tire Registration or by contacting CIMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2365 at 330-794-9190. NON-FORD OR LINCOLN MERCURY VEHICLES WITH FIRESTONE WILDERNESS AT Non-Ford or Lincoln Mercury vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires installed by a Certified Tire Dealer (AtW or Ford Tire Program) are eligible for replacement. The repair should be submitted using a Warranty/ESP claim type form. The dealer must enter Program Code "P19", this will allow the repair to be submitted without a VIN. The causal part must be TIRE, with the actual part numbers for reimbursement at dealer cost plus 25%, and use actual time for labor reimbursement. These types of claims cannot be submitted as an Owner Notification Repair type. Attachment II - Parts and Labor Information LABOR ALLOWANCES NON-AtW DEALERS SERVICING IN-STOCK UNITS OR CUSTOMER VEHICLES NOTE: Non-Certified Tire Dealers (AtW or Ford Tire Program) who have vehicles in stock, or customer vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires must send the vehicle to a Certified Tire Dealer (AtW or Ford Tire Program), or an approved tire retailer participating in the program to have the tire replacement performed. The non-Certified Tire Dealer (AtW or Ford Tire Program) will submit a 01B77 ONP claim using the miscellaneous expense code of "SCHP" (with a dollar value of $15.00 to cover administrative costs). Do not claim the "Admin" labor operation. PARTS REQUIREMENTS Tire Ordering Information ^ Dealers are required to install only tires from the Approved Tire List for vehicles originally equipped with 15-, 16-, and 17-inch Firestone Wilderness AT tires. Dealers should immediately order replacement tires for inventory. ^ Certified Tire Dealers will order replacement tires through normal channels. ^ Dealers not authorized for the Around the Wheel Program will not participate in this recall. Dealers may call the Ford Tire Hotline 1-888-353-3251 for enrollment and program details. TIRE AVAILABILITY: All dealers should check QCDealer.com daily for updates to the approved tires list. Distributors and tire retailers will allocate tires as best they can on a daily basis. Your dealership should do the following to ensure that you are able to secure your fair allotment of these limited volumes: Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2366 ^ Contact your Ford authorized facing distributor(s) for each tire manufacturer. ^ Contact your Ford authorized facing tire retailers for each tire manufacturer. ^ Review with these supply points the volume of tires you need to ensure you have tires ready to fill orders with every supply point. Questions not addressed by above sources should be directed to your market area team. CUSTOMER WAIT LISTS: Dealers should create a customer wait list and record: Customer name ^ Address and phone number ^ Vehicle make ^ Model year ^ Mileage ^ Tire size NOTE: Customers should be prioritized to replace oldest tires first. WAIT LIST SURVEY Please fill out the Firestone Tire Survey in the Management Report Section of QCDealer weekly. It is critical that you answer the questions as accurately as possible as the survey results will be used to help determine the level of production from the tire manufacturers. DEALER PRICE For latest prices on replacement tires, refer to the most recent Ford Motor Company Tire Price List. PROCEDURE FOR CLAIMING REFUNDS FOR TIRES PURCHASED AFTER NOVEMBER 15, 2001 The following procedure applies to tires purchased after November 15, 2001: 1. Determine if the customer should receive special consideration based on owner loyalty, special circumstance cc, etc. 2. If the customer is eligible for special consideration the dealer will call the Special Service Support Center at 1800-325-5621 to request an authorization code. 3. The Special Service Support Center representative will ask for the following: ^ Customer Name ^ VIN ^ Date of repair ^ Original copy of invoice (be prepared to fax) 4. If the customer qualifies for a refund, the Special Service Support Center will provide your dealer with an authorization code. 5. Your dealer will input a claim with the authorization code (authorization code must be included to receive payment). 6. After the dealer receives payment for the claim, the dealer will then send the refund to the customer. NOTE: If the Special Service Support Center determines that the customer does not qualify for a refund, no authorization code will be given. Any appeals must be made by the dealer to the appropriate field representative Attachment III - Technical Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2367 AFFECTED VEHICLES: REFER TO DEALER LETTER FOR AFFECTED TIRES AND VEHICLES OVERVIEW This program details the replacement of 15-, 16-, and 17-inch Firestone Wilderness AT tires regardless of production plant. You will need to perform a DOT code inspection prior to replacing the 15, 16, or 17-inch Wilderness AT tires. NOTE: When lowering or raising an under-vehicle spare, DO NOT use power tools. Also make sure that the spare is secure under the vehicle, and not swinging loose. The spare tire winch will ratchet when the tire is completely stowed. NOTE: Radial ATX "TEMPORARY USE" spare tires are not included under this program, and should not be replaced as part of this program. NOTE: Spare tires should always be replaced with the exact same size tire; otherwise the spare tire may not store in the proper position on the vehicle. INSPECTION 1. Inspect the vehicle tires (including the spare tire) for the presence of Firestone Wilderness AT tires. 2. If Firestone Wilderness AT tires are present replace them with a suitable replacement from the "Approved Tire List". Note: There may be cases where a vehicle is equipped with 15-, 16-, or 17-inch Firestone Wilderness AT tire sizes that are not included on the Ford-approved replacement list. These tires are not original equipment (OE) and, therefore, will not have an approved tire listed. In such cases, it is recommended that the customer install the proper OE tire, or have a tire of suitable quality installed. Reference the vehicle's "Safety Certification Label" and current "Ford Motor Company Tire Price Guide" for OE or suitable replacement recommendations. 3. If only one Firestone Wilderness AT road tire is present on the vehicle, you will need to replace the opposing tire on the same axle. However, if one (1) front and one (1) rear tire are Wilderness AT you would not automatically replace all four (4) tires instead, you would replace the two (2) Wilderness AT tires and place them on the same axle. 4. Record the DOT code from each removed tire(s) on the repair order. 5. Tires that are removed from vehicles must immediately be made unusable by either cutting through the bead and DOT code with bolt cutters, or drilling a one-inch diameter hole (directly on the DOT code to make the code unreadable) in the sidewall. 6. Adjust all tires to the proper inflation pressure, and release the vehicle. For specifications, refer to the vehicle Owner's Manual or the vehicle certification label located on the driver's door opening. NOTE: Tires that are removed from vehicles under this program, and those in dealer inventory must immediately be made unusable by either cutting the bead with bolt cutters or drilling a 1" diameter hole (directly on the DOT code to make the code unreadable) in the sidewall. Defacing the DOT code will prevent the tire from being used for an additional refund request. NOTE: If the vehicle is a 4X4, and is equipped with non-Firestone Wilderness AT tires on one axle, and the replacement tires for the Firestone equipped axle causes a mismatch with the existing non-Firestone axle, the customer is responsible for the tire mismatch. If the customer refuses to purchase matching tires to correct the mismatch - the dealer should annotate the repair order to reflect the customer's decision. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01S18 > Jun > 01 > Recall - Passenger Side Tire Inspection Technical Service Bulletin # 01S18 Date: 010618 Recall - Passenger Side Tire Inspection SAFETY RECALL 01S18 Certain 2002 Explorer and Mountaineer Vehicles - Passenger Side Tires Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01S18 > Jun > 01 > Recall - Passenger Side Tire Inspection > Page 2372 Supplement # 1 - Attachment I OASIS You must use OASIS to determine if a vehicle is eligible for this recall. NOTE: Many of the vehicles affected by this program are also affected by Special Service Instruction 01T02. Please check OASIS and if applicable, complete both actions during one customer visit. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer Recall/ONP Involved Unit Listing available on QCDealer.com. Also, correct other affected vehicles identified in OASIS which are brought to your dealership. DEALER-OWNER CONTACT Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01S18 > Jun > 01 > Recall - Passenger Side Tire Inspection > Page 2373 Immediately contact any of your affected owners whose names are not on your VIN list but identified in OASIS. Give the owner a copy of the Owner Letter and schedule a service date. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ Enter information on a recall claim type. DO NOT use a Warranty Claim type. ^ Program code 01S18. ^ Enter the full part number of the replacement tire with the quantity of tires replaced. Payment will be at the same price level as tire warranty. ^ Use the appropriate Labor Operation(s) from Attachment II. ^ Tire disposal and applicable local waste tax will be reimbursed. Enter "OTHER" in the Miscellaneous Expense area of the claim with the actual cost. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs applicable to this recall, which were made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. NOTE: Before this recall was announced, some customers may have had this tire concern and were refused coverage because the damage was believed to have been caused by a road hazard. If the refund request is for tire damage that may have been caused by this cut tire condition, a refund should be approved. RENTAL VEHICLES Ford Motor Company will pay for a rental vehicle if tires need to be installed. Fuel and insurance will be at the owner's expense. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "RENTAL", plus the number of days the vehicle was used, in the Miscellaneous Expense area of the claim. Supplement # 1 - Attachment II LABOR ALLOWANCES Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01S18 > Jun > 01 > Recall - Passenger Side Tire Inspection > Page 2374 PARTS REQUIREMENTS NOTE: If the tires on the vehicle are any other brand, please contact the Special Service Support Center at 1-800-325-5621. TIRE ORDERING Ford Tire Program/Atw Dealers You must have an order number to obtain replacement tires under this program. (Do not contact the Special Service Support Center to obtain an order number.) 1. Contact the Ford Tire Hot Line at 1-888-353-3251 to obtain an order number. Be prepared to provide the following information: ^ Your name ^ Dealer P & A code 2. After you have an order number, contact your authorized tire distributor and order replacement tires. DEALERSHIPS ELIGIBLE TO REPLACE TIRES UNDER THIS PROGRAM All Ford and Lincoln Mercury dealers enrolled on the AtW or Ford Tire Program are eligible to complete tire replacements under this program. Ford dealers interested in joining the Ford Tire Program can enroll from QCDealer.com by clicking on the Tire Center and filling out the on-line enrollment form or by calling the Ford Tire Hot Line at 1-888-353-3251 for enrollment and program details. TIRE PRICING For latest prices on replacement tires, refer to the most recent Ford Motor Company Quarterly Tire Price Guide. TIRE DISPOSAL Damaged tires that are removed from vehicles must immediately be made unusable by either cutting the bead with bolt cutters or drilling a one-inch diameter hole in the sidewall. After mutilating the tire, use your normal tire disposal procedures. Supplement # 1 - Attachment III This document details the inspection of the passenger side tires for a cut or slice in the side of the tread area (side facing curb only) which may have occurred during vehicle assembly. Any tire found with a cut or slice must be replaced. INSPECTION NOTE: Only Michelin Cross Terrain, Goodyear Eagle LS and Goodyear Wrangler AP tires are included in this inspection. If the tires on the vehicle are any other brand, contact the Special Service Support Center at 1-800-325-5621 for further instruction. NOTE: If the vehicle has more than 8,000 km (5,000 miles), all four (4) road tires must be inspected because they may have been rotated. 1. Park the vehicle so the passenger side tires are accessible and you have adequate lighting for the inspection. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01S18 > Jun > 01 > Recall - Passenger Side Tire Inspection > Page 2375 2. Visually inspect the passenger side tires along the tread area on the side of the tire for a cut or slice. See Figure 1. Scuffs in the tread and/or sidewall area are acceptable and should not be a cause for concern. 3. If the vehicle has more than 8,000 km (5,000 miles), inspect all four (4) road tires (do not inspect spare). 4. Move the vehicle forward 62 cm (2 feet) so that the tire is rotated one-half revolution. 5. Inspect the tires again. 6. If any tire is found cut or sliced (which must be replaced), refer to the following Special Note before you begin to replace any tires. SPECIAL NOTE: If one or two tires are to be replaced, the tread depth of the non-replaced tires must be checked. This must be done to determine if additional tires must be replaced. TIRE DISPOSAL Tires that are removed from the vehicle must immediately be made unusable by either cutting the bead with bolt cutters or drilling a one-inch diameter hole in the sidewall. Dispose of damaged tires using your normal tire disposal method. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01S18 > Jun > 01 > Recall - Passenger Side Tire Inspection > Page 2376 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01S18 > Jun > 01 > Recall - Passenger Side Tire Inspection > Page 2377 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01S18 > Jun > 01 > Recall - Passenger Side Tire Inspection > Page 2378 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01S18 > Jun > 01 > Recall - Passenger Side Tire Inspection > Page 2379 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01S18 > Jun > 01 > Recall - Passenger Side Tire Inspection > Page 2380 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > NHTSA01V171000 > May > 01 > Recall 01V171000: Tire Defects Tires: Recalls Recall 01V171000: Tire Defects Vehicle Description: Sport utility vehicles. The right side tires may have horizontal cuts on the edge of the tread that could have occurred during vehicle assembly. Over time, the tire could fail, increasing the risk of a crash. Dealers will inspect the tires and, if any slices are found, the cut tires will be replaced. Owner notification began June 7, 2001. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment > Page 2390 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement Technical Service Bulletin # 01B77 Date: 011001 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2395 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2396 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2397 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2398 Attachment I - Administrative Information OASIS OASIS must be used to determine vehicle eligibility. IMPORTANT: When an eligible vehicle is at the dealership for service, OASIS must be contacted to determine if Owner Notification Program 01B77 is open. If 01B77 is listed in OASIS as open, it is important that the vehicle is inspected for eligible tires. If the eligible vehicle is not equipped with 15-, 16-, or 17-inch Firestone Wilderness AT tires a claim must be submitted using labor operation 01B77A to close the program. If an affected vehicle does not have 01B77 open, this may indicate that a refund or tire replacement has already been processed on this vehicle. Some Ford and Lincoln Mercury vehicles not listed in the AFFECTED TIRES AND VEHICLES list may have 15-, 16-, or 17-inch Firestone Wilderness AT tires installed. These vehicles are covered under this program, but will not be active in OASIS. Contact the Special Service Support Center at 1-800-325-5621 to obtain prior approval before performing the repair or issuing a refund. This will insure that a previous repair/refund has not been performed on the vehicle. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII User Manual for claims preparation and submission information. ^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type. ^ Program code 01B77. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2399 ^ Enter the full part number of the replacement tire with the quantity of tires replaced. Tires will be reimbursed at AtW Dealer cost + 25% (wheel weights and valve stems incl.). ^ Use the appropriate labor operation(s) from Attachment II. ^ Freight is reimbursable at actual cost in the miscellaneous expense area of the claim. NOTE: Freight is only reimbursable for rural dealers whose only means of acquiring tires is by having them shipped in via common carrier. Dealers are encouraged to arrange for shipment of 4 or more tires at a time. ^ Dealers can no longer claim tire disposal for ONP 01B77. See the "National Tire Recovery and Recycle Program". You may still claim any applicable local waste tax - enter OTHER in the expense area of the claim with the actual cost. ^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires on the diagnostic code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the space provided in the diagnostic code area, use the technician comment area to complete the data entry. RELATED DAMAGE Vehicle damage caused by a tire related failure is not covered by this program. Refer to the Warranty and Policy Manual for proper claiming procedure for vehicles covered by the Ford Bumper-to-Bumper Tire Warranty (model years 2001 and 2002). All other pre-2001 model year vehicles with alleged tire related vehicle damage should be handled through the Firestone claims process, or by referring the customers to their insurance company. Damage related to replacement of tires should be handled as described in the Warranty and Policy Manual. OWNER REFUND With the increased availability of replacement tires, it will no longer be necessary for customers to pay out-of-pocket expenses for tires. Therefore, refund requests for tires purchased after November 15, 2001 will no longer be granted. Owners will be notified of the refund expiration date and will be directed to a Ford or Mercury dealer They are directed to an authorized retailer only if the Ford or Mercury dealer cannot meet their scheduling needs or tires are not in stock. All Ford and Mercury dealers (AtW and non-AtW dealers) are required to process refunds for customers who purchase tires prior to November 15, 2001. The following rules apply to refunds for tires purchased from August 1, 2001 through November 15, 2001: Refunds will be processed for vehicles listed under "AFFECTED TIRES AND VEHICLES", and for other Ford and Lincoln Mercury vehicles that have 15-. 16-, or 17-inch Wilderness AT tires installed. ^ The customer must provide the original paid receipt (a copy of their paid receipt is acceptable on an exception basis in instances where the owner requires the original for another purpose (e.g. extended tire warranty or purchase rebate). The dealer will attach the receipt to the dealer file copy of the refund claim (see claim instructions below). ^ Dealers will be reimbursed to immediately disable tires returned for a refund (see claiming instructions for refunds and Attachment II for labor operations). ^ The tires must be purchased August 1, 2000 through November 15, 2001 to be eligible for a refund (through October 31, 2001 for 1995 and 1996 F-150 owners). ^ Customers requesting refunds for tire replacement May 22, 2001 through November 15, 2001 must provide either: NOTE: This does not apply to 1995 and 1996 F-150 customers. ^ The Firestone Wilderness AT tires that were replaced. Returned tire(s) are to be disabled by the dealership. Ford will reimburse the dealer to disable (see claim instructions below and use labor operation 01B77G). If tires are brought in for refund with the DOT codes missing dealers should not process the refund. ^ A section of the old tire(s) containing the DOT codes from each of the Firestone Wilderness AT tires that were replaced (To be cut from the Wilderness AT tires that were replaced by the outside repair facility) (use labor operation 01B77L). Dealers should deface (cut in pieces or make code unreadable) the DOT sections of the tire so they cannot be used to obtain another refund. If sections are brought in for refund with the DOT code defaced dealers should not process the refund. NOTE: The DOT Code Identification Guide has been developed to help dealers determine if the DOT sections returned to the dealership are from 15-, 16-, Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2400 or 17-inch Firestone Wilderness AT tires. Use the DOT Code Identification Guide in conjunction with the bulletin section "What if the Vehicle has a Mix of Affected and Non-Affected Tires" to determine how many tires are eligible for refund. NOTE: Ford will allow customers to file for a refund (with or without tires) for tires purchased after May 22 through June 30, 2001 because customers may not have tires to turn in. Customers must provide a paid receipt indicating tire replacement before July 1, 2001 in order to process a refund without tires or DOT sections. Customers who purchase tires after June 30, 2001 must provide tires or DOT sections. Ford will reimburse customers the following amounts: ^ Tires purchased from August 1, 2000 through May 22, 2001, the actual cost as stated on their paid receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes. ^ (1995 and 1996 F-150 vehicle only) Tires purchased from August 1, 2000 through October 31, 2001, the actual cost as stated on their paid receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes. No DOT section required. ^ Tires purchased May 23, 2001 through November 15, 2001, the actual cost as stated on the receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes up to a maximum of $110 per tire for 15 inch, and $130 per tire for 16 and 17 inch tires. ^ Refunds will not be granted for tires purchased after November 15, 2001. Note: If an owner pays for the replacement of their tires after November 15, 2001, the dealer may handle on a case by case basis following the procedure in Attachment II. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2401 CLAIMS PREPARATION FOR REFUNDS (USE THIS PROCEDURE FOR ALL REFUND REQUESTS) NOTE: Tires must be purchased prior to November 15, 2001 ^ Enter claims using DWE. ^ Refer to ACESII User Manual for claims preparation and submission information. ^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type. ^ Program code 01B77. ^ When a customer brings in their old tires and is seeking a refund, use labor operation 01B77G (disable) and 01B77L (refund administration allowance) from Attachment II. ^ If a customer brings in the old DOT codes removed from the old tires - use labor operation 01B77L only. ^ The Miscellaneous Expense Code "ADMIN" will not be accepted under this program. A labor operation 01B77L has been provided to cover administrative costs. ^ Enter REFUND in the miscellaneous area of the claim. ^ Dealers will no longer be able to claim tire disposal for ONP 01B77. See the "National Tire Recovery and Recycle Program" You may still claim any applicable local waste tax - enter OTHER in the expense area of the claim with the actual cost. ^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires in the diagnostic code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the space provided in the diagnostic code area, use the technician comment area to complete the data entry. If the tires were replaced prior to May 23, 2001 (or November 1, 2001 for 1995 and 1996 F150 customers) the DOT may not be available, in this case record the brand, make and size of the tires in the technician comments area of the claim. RENTAL CARS TAP allowances have been increased specifically for this owner notification program. Refer to Don Brunner letter. DOT REGISTRATION OF NEW TIRES Dealers are required to register the DOT number of every tire sold to meet federal tire registration requirements. Ford has established a partnership with CIMS to assist dealers in registering these DOT codes. Information is available on QCDealer.com under CIMS Tire Registration or by contacting CIMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2402 at 330-794-9190. NON-FORD OR LINCOLN MERCURY VEHICLES WITH FIRESTONE WILDERNESS AT Non-Ford or Lincoln Mercury vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires installed by a Certified Tire Dealer (AtW or Ford Tire Program) are eligible for replacement. The repair should be submitted using a Warranty/ESP claim type form. The dealer must enter Program Code "P19", this will allow the repair to be submitted without a VIN. The causal part must be TIRE, with the actual part numbers for reimbursement at dealer cost plus 25%, and use actual time for labor reimbursement. These types of claims cannot be submitted as an Owner Notification Repair type. Attachment II - Parts and Labor Information LABOR ALLOWANCES NON-AtW DEALERS SERVICING IN-STOCK UNITS OR CUSTOMER VEHICLES NOTE: Non-Certified Tire Dealers (AtW or Ford Tire Program) who have vehicles in stock, or customer vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires must send the vehicle to a Certified Tire Dealer (AtW or Ford Tire Program), or an approved tire retailer participating in the program to have the tire replacement performed. The non-Certified Tire Dealer (AtW or Ford Tire Program) will submit a 01B77 ONP claim using the miscellaneous expense code of "SCHP" (with a dollar value of $15.00 to cover administrative costs). Do not claim the "Admin" labor operation. PARTS REQUIREMENTS Tire Ordering Information ^ Dealers are required to install only tires from the Approved Tire List for vehicles originally equipped with 15-, 16-, and 17-inch Firestone Wilderness AT tires. Dealers should immediately order replacement tires for inventory. ^ Certified Tire Dealers will order replacement tires through normal channels. ^ Dealers not authorized for the Around the Wheel Program will not participate in this recall. Dealers may call the Ford Tire Hotline 1-888-353-3251 for enrollment and program details. TIRE AVAILABILITY: All dealers should check QCDealer.com daily for updates to the approved tires list. Distributors and tire retailers will allocate tires as best they can on a daily basis. Your dealership should do the following to ensure that you are able to secure your fair allotment of these limited volumes: Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2403 ^ Contact your Ford authorized facing distributor(s) for each tire manufacturer. ^ Contact your Ford authorized facing tire retailers for each tire manufacturer. ^ Review with these supply points the volume of tires you need to ensure you have tires ready to fill orders with every supply point. Questions not addressed by above sources should be directed to your market area team. CUSTOMER WAIT LISTS: Dealers should create a customer wait list and record: Customer name ^ Address and phone number ^ Vehicle make ^ Model year ^ Mileage ^ Tire size NOTE: Customers should be prioritized to replace oldest tires first. WAIT LIST SURVEY Please fill out the Firestone Tire Survey in the Management Report Section of QCDealer weekly. It is critical that you answer the questions as accurately as possible as the survey results will be used to help determine the level of production from the tire manufacturers. DEALER PRICE For latest prices on replacement tires, refer to the most recent Ford Motor Company Tire Price List. PROCEDURE FOR CLAIMING REFUNDS FOR TIRES PURCHASED AFTER NOVEMBER 15, 2001 The following procedure applies to tires purchased after November 15, 2001: 1. Determine if the customer should receive special consideration based on owner loyalty, special circumstance cc, etc. 2. If the customer is eligible for special consideration the dealer will call the Special Service Support Center at 1800-325-5621 to request an authorization code. 3. The Special Service Support Center representative will ask for the following: ^ Customer Name ^ VIN ^ Date of repair ^ Original copy of invoice (be prepared to fax) 4. If the customer qualifies for a refund, the Special Service Support Center will provide your dealer with an authorization code. 5. Your dealer will input a claim with the authorization code (authorization code must be included to receive payment). 6. After the dealer receives payment for the claim, the dealer will then send the refund to the customer. NOTE: If the Special Service Support Center determines that the customer does not qualify for a refund, no authorization code will be given. Any appeals must be made by the dealer to the appropriate field representative Attachment III - Technical Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2404 AFFECTED VEHICLES: REFER TO DEALER LETTER FOR AFFECTED TIRES AND VEHICLES OVERVIEW This program details the replacement of 15-, 16-, and 17-inch Firestone Wilderness AT tires regardless of production plant. You will need to perform a DOT code inspection prior to replacing the 15, 16, or 17-inch Wilderness AT tires. NOTE: When lowering or raising an under-vehicle spare, DO NOT use power tools. Also make sure that the spare is secure under the vehicle, and not swinging loose. The spare tire winch will ratchet when the tire is completely stowed. NOTE: Radial ATX "TEMPORARY USE" spare tires are not included under this program, and should not be replaced as part of this program. NOTE: Spare tires should always be replaced with the exact same size tire; otherwise the spare tire may not store in the proper position on the vehicle. INSPECTION 1. Inspect the vehicle tires (including the spare tire) for the presence of Firestone Wilderness AT tires. 2. If Firestone Wilderness AT tires are present replace them with a suitable replacement from the "Approved Tire List". Note: There may be cases where a vehicle is equipped with 15-, 16-, or 17-inch Firestone Wilderness AT tire sizes that are not included on the Ford-approved replacement list. These tires are not original equipment (OE) and, therefore, will not have an approved tire listed. In such cases, it is recommended that the customer install the proper OE tire, or have a tire of suitable quality installed. Reference the vehicle's "Safety Certification Label" and current "Ford Motor Company Tire Price Guide" for OE or suitable replacement recommendations. 3. If only one Firestone Wilderness AT road tire is present on the vehicle, you will need to replace the opposing tire on the same axle. However, if one (1) front and one (1) rear tire are Wilderness AT you would not automatically replace all four (4) tires instead, you would replace the two (2) Wilderness AT tires and place them on the same axle. 4. Record the DOT code from each removed tire(s) on the repair order. 5. Tires that are removed from vehicles must immediately be made unusable by either cutting through the bead and DOT code with bolt cutters, or drilling a one-inch diameter hole (directly on the DOT code to make the code unreadable) in the sidewall. 6. Adjust all tires to the proper inflation pressure, and release the vehicle. For specifications, refer to the vehicle Owner's Manual or the vehicle certification label located on the driver's door opening. NOTE: Tires that are removed from vehicles under this program, and those in dealer inventory must immediately be made unusable by either cutting the bead with bolt cutters or drilling a 1" diameter hole (directly on the DOT code to make the code unreadable) in the sidewall. Defacing the DOT code will prevent the tire from being used for an additional refund request. NOTE: If the vehicle is a 4X4, and is equipped with non-Firestone Wilderness AT tires on one axle, and the replacement tires for the Firestone equipped axle causes a mismatch with the existing non-Firestone axle, the customer is responsible for the tire mismatch. If the customer refuses to purchase matching tires to correct the mismatch - the dealer should annotate the repair order to reflect the customer's decision. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01S18 > Jun > 01 > Recall - Passenger Side Tire Inspection Technical Service Bulletin # 01S18 Date: 010618 Recall - Passenger Side Tire Inspection SAFETY RECALL 01S18 Certain 2002 Explorer and Mountaineer Vehicles - Passenger Side Tires Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01S18 > Jun > 01 > Recall - Passenger Side Tire Inspection > Page 2409 Supplement # 1 - Attachment I OASIS You must use OASIS to determine if a vehicle is eligible for this recall. NOTE: Many of the vehicles affected by this program are also affected by Special Service Instruction 01T02. Please check OASIS and if applicable, complete both actions during one customer visit. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer Recall/ONP Involved Unit Listing available on QCDealer.com. Also, correct other affected vehicles identified in OASIS which are brought to your dealership. DEALER-OWNER CONTACT Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01S18 > Jun > 01 > Recall - Passenger Side Tire Inspection > Page 2410 Immediately contact any of your affected owners whose names are not on your VIN list but identified in OASIS. Give the owner a copy of the Owner Letter and schedule a service date. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ Enter information on a recall claim type. DO NOT use a Warranty Claim type. ^ Program code 01S18. ^ Enter the full part number of the replacement tire with the quantity of tires replaced. Payment will be at the same price level as tire warranty. ^ Use the appropriate Labor Operation(s) from Attachment II. ^ Tire disposal and applicable local waste tax will be reimbursed. Enter "OTHER" in the Miscellaneous Expense area of the claim with the actual cost. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs applicable to this recall, which were made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. NOTE: Before this recall was announced, some customers may have had this tire concern and were refused coverage because the damage was believed to have been caused by a road hazard. If the refund request is for tire damage that may have been caused by this cut tire condition, a refund should be approved. RENTAL VEHICLES Ford Motor Company will pay for a rental vehicle if tires need to be installed. Fuel and insurance will be at the owner's expense. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "RENTAL", plus the number of days the vehicle was used, in the Miscellaneous Expense area of the claim. Supplement # 1 - Attachment II LABOR ALLOWANCES Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01S18 > Jun > 01 > Recall - Passenger Side Tire Inspection > Page 2411 PARTS REQUIREMENTS NOTE: If the tires on the vehicle are any other brand, please contact the Special Service Support Center at 1-800-325-5621. TIRE ORDERING Ford Tire Program/Atw Dealers You must have an order number to obtain replacement tires under this program. (Do not contact the Special Service Support Center to obtain an order number.) 1. Contact the Ford Tire Hot Line at 1-888-353-3251 to obtain an order number. Be prepared to provide the following information: ^ Your name ^ Dealer P & A code 2. After you have an order number, contact your authorized tire distributor and order replacement tires. DEALERSHIPS ELIGIBLE TO REPLACE TIRES UNDER THIS PROGRAM All Ford and Lincoln Mercury dealers enrolled on the AtW or Ford Tire Program are eligible to complete tire replacements under this program. Ford dealers interested in joining the Ford Tire Program can enroll from QCDealer.com by clicking on the Tire Center and filling out the on-line enrollment form or by calling the Ford Tire Hot Line at 1-888-353-3251 for enrollment and program details. TIRE PRICING For latest prices on replacement tires, refer to the most recent Ford Motor Company Quarterly Tire Price Guide. TIRE DISPOSAL Damaged tires that are removed from vehicles must immediately be made unusable by either cutting the bead with bolt cutters or drilling a one-inch diameter hole in the sidewall. After mutilating the tire, use your normal tire disposal procedures. Supplement # 1 - Attachment III This document details the inspection of the passenger side tires for a cut or slice in the side of the tread area (side facing curb only) which may have occurred during vehicle assembly. Any tire found with a cut or slice must be replaced. INSPECTION NOTE: Only Michelin Cross Terrain, Goodyear Eagle LS and Goodyear Wrangler AP tires are included in this inspection. If the tires on the vehicle are any other brand, contact the Special Service Support Center at 1-800-325-5621 for further instruction. NOTE: If the vehicle has more than 8,000 km (5,000 miles), all four (4) road tires must be inspected because they may have been rotated. 1. Park the vehicle so the passenger side tires are accessible and you have adequate lighting for the inspection. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01S18 > Jun > 01 > Recall - Passenger Side Tire Inspection > Page 2412 2. Visually inspect the passenger side tires along the tread area on the side of the tire for a cut or slice. See Figure 1. Scuffs in the tread and/or sidewall area are acceptable and should not be a cause for concern. 3. If the vehicle has more than 8,000 km (5,000 miles), inspect all four (4) road tires (do not inspect spare). 4. Move the vehicle forward 62 cm (2 feet) so that the tire is rotated one-half revolution. 5. Inspect the tires again. 6. If any tire is found cut or sliced (which must be replaced), refer to the following Special Note before you begin to replace any tires. SPECIAL NOTE: If one or two tires are to be replaced, the tread depth of the non-replaced tires must be checked. This must be done to determine if additional tires must be replaced. TIRE DISPOSAL Tires that are removed from the vehicle must immediately be made unusable by either cutting the bead with bolt cutters or drilling a one-inch diameter hole in the sidewall. Dispose of damaged tires using your normal tire disposal method. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01S18 > Jun > 01 > Recall - Passenger Side Tire Inspection > Page 2413 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01S18 > Jun > 01 > Recall - Passenger Side Tire Inspection > Page 2414 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01S18 > Jun > 01 > Recall - Passenger Side Tire Inspection > Page 2415 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01S18 > Jun > 01 > Recall - Passenger Side Tire Inspection > Page 2416 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01S18 > Jun > 01 > Recall - Passenger Side Tire Inspection > Page 2417 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > NHTSA01V171000 > May > 01 > Recall 01V171000: Tire Defects Tires: All Technical Service Bulletins Recall 01V171000: Tire Defects Vehicle Description: Sport utility vehicles. The right side tires may have horizontal cuts on the edge of the tread that could have occurred during vehicle assembly. Over time, the tire could fail, increasing the risk of a crash. Dealers will inspect the tires and, if any slices are found, the cut tires will be replaced. Owner notification began June 7, 2001. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 05-3-4 > Feb > 05 > Body - Moonroof Squeak or Rattle Noise Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 05-3-4 > Feb > 05 > Body - Moonroof Squeak or Rattle Noise > Page 2427 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 2428 Tires: Specifications Tire Tread Depth P235/70R16 A/S .................................................................................................................................. ................................................ 9.0 mm (0.35 inch) P255/70R16 A/T .................................................. ............................................................................................................................ 110.7 mm (0.42 inch) Tire Inflation Tires ..................................................................................................................................... See safety certification sticker located on driver door jamb. Tire Runout Specifications Aluminum Max.Radial Runout .............................................................................................................................. ..................................... 1.02 mm (0.040 inch) Max. Lateral Runout ................................................... ............................................................................................................... 1.02 mm (0.040 inch) Steel Max. Radial Runout ............................................................................................................................. ..................................... 1.02 mm (0.040 inch) Max. Lateral Runout ................................................... ............................................................................................................... 1.02 mm (0.040 inch) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 2433 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 2434 Wheels: Specifications Wheel Machined Aluminum ............................................................................................................................ ................................................................. (16 x 7) Maximum Balance Weight (Total Of Inner And Outer Wheel Flange) ........................................................................................ 170 grams (6.0 ounces) Wheel Offset .......................................................................................................................... ............................................................... 12 mm (0.48 inch) Wheel Bolt Circle Runout .............................................................................................................................................................. 0.25 mm (0.OO9 inch) Wheel Rim Runout Aluminum Max. Radial Runout ............................................................................................................................. ..................................... 1.28 mm (0.050 inch) Max.Lateral Runout .................................................... ............................................................................................................... 0.50 mm (0.019 inch) Steel Max.Radial Runout .............................................................................................................................. ..................................... 0.30 mm (0.010 inch) Max.Lateral Runout .................................................... ............................................................................................................... 1.02 mm (0.040 inch) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection Wheel Bearing: Testing and Inspection Wheel Bearing Inspection 1. Raise the vehicle until the tire is off the floor. 2. NOTE: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow movement of the tire and wheel assembly. Grasp each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 3. If the tire and wheel (hub) is loose on the wheel spindle or does not rotate freely, perform one of the following actions. ^ On 4x2 vehicles, adjust the front wheel bearings. ^ On 4x4 vehicles, install a new wheel hub. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Wheel Nuts .......................................................................................................................................... ................................................. 135 Nm (100 ft. lbs.) Wheel Stud And Wheel Nuts ........................... ......................................................................................................................................... 1/2-20-19 mm hex Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Wheel Fastener: Service and Repair Front Wheel Studs Removal 1. Remove the wheel and tire assembly. 2. CAUTION: When removing the disc brake caliper, never allow it to hang from the brake hose. Provide a suitable support. Remove the brake caliper and anchor plate as an assembly. 3. Remove the brake disc and hub as follows: 1 Remove the hub grease cap. 2 Remove the cotter pin. 3 Remove the nut retainer. 4 Remove the spindle nut. 5 Remove the front wheel outer bearing retainer washer. 6 Remove the outer front wheel bearing. 7 Remove the brake disc and hub. 4. CAUTION: Place shop towels between the pry bars and the brake disc to prevent damage to the disc surface. Using two pry bars, remove the ABS sensor ring. Discard the ABS sensor ring. 5. Using a suitable press, remove the wheel stud from the brake disc and hub. Installation Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 2443 1. Using a suitable press, install the wheel stud in the brake disc and hub. 2. CAUTION: When installing the ABS sensor ring, make sure the sensor ring is pressed on straight. Position a new ABS sensor ring on the hub. Using a cylinder with 79 mm (3.16 inch) inside diameter and 96 mm (3.84 inch) outside diameter, press the ring onto the hub until the ring seats against the shoulder in the hub. 3. Install the brake disc and hub. 1 Position the brake disc and hub. 2 Install the outer front wheel bearing. 3 Install the front wheel outer bearing retainer washer. 4 Install the spindle nut. 4. Tighten the spindle nut while rotating the brake disc and hub. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 2444 5. Loosen the spindle nut. 6. Tighten the spindle nut while rotating the brake disc and hub. 7. Install the following components: 1 Install the nut retainer. 2 Install the cotter pin. 3 Install the hub grease cap. 8. Install the caliper and anchor plate assembly. 9. Install the wheel and tire assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 2445 Wheel Fastener: Service and Repair Rear Wheel Studs Special Tool(s) Special Tools Removal CAUTION: Never use a hammer to remove the wheel stud. Damage to the axle flange, hub flange, wheel bearing or hub bearing can result. 1. Raise the vehicle and install safety stands. 2. Remove the wheel and tire assembly. 3. Remove the rear disc brake caliper, rear disc support bracket and brake disc, if so equipped. Support the rear disc brake caliper with safety wire. 4. Using the C-Frame and Screw Assembly, press the wheel stud from its seat and discard. Installation CAUTION: Never use air tools to install wheel studs. The serrations can be stripped from the stud. 1. Insert a new wheel stud in the hole in the axle flange, making sure the serrations are aligned with those made by the original wheel stud. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 2446 2. Seat new wheel studs in the axle flange. - Place four flat washers over the outside end of the wheel stud. - Thread a standard wheel nut with the flat side against the washers. - Tighten the wheel nut until the wheel stud head seats against the back side of the flange. 3. Remove the wheel nut and flatwashers. 4. Install the brake disc, rear disc support bracket and the rear disc brake caliper, if so equipped. 5. Install the wheel and tire assembly. 6. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation Vehicle Lifting: Description and Operation JACKING WARNING: ^ DO NOT RUN THE ENGINE WHEN JACKING THE VEHICLE. THE WHEELS CONTACTING THE GROUND COULD CAUSE THE VEHICLE TO MOVE. ^ MAKE SURE THE JACK AND JACK STANDS ARE CORRECTLY LOCATED TO PREVENT THE VEHICLE FROM FALLING. ^ A WHEEL CHOCK SHOULD BE USED TO PREVENT THE VEHICLE FROM ROLLING AND FALLING OFF THE JACK. ^ WHEN ONE OF THE REAR WHEELS IS OFF THE GROUND, THE TRANSMISSION ALONE WILL NOT PREVENT THE VEHICLE FROM MOVING OR SLIPPING OFF THE JACK, EVEN IF THE TRANSMISSION IS IN P (PARK) (AUTOMATIC TRANSMISSION) OR REVERSE (MANUAL TRANSMISSION). Jacking Points - Front Jacking Points - Front The front jacking point is a tab that extends from the lower control arm. Jacking Points - Rear The rear jacking points are located on the rear axle tube CAUTION: Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and adjoining differential housing surface can occur if a floor jack or any lifting device is allowed to contact the cover at any point where the cover joins the housing. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation > Page 2450 LIFTING Lifting Points - Front 1. The front lifting points are located underneath the number one body mount bracket. CAUTION: ^ Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and adjoining differential housing surface can occur if a floor jack or any lifting device is allowed to contact the cover at any point where the cover joins the housing. ^ Damage to the suspension, fuel tank, exhaust or steering linkage components can occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. Lifting Point - Rear 1. The rear lifting point is the bottom surface of the leaf spring front eye. CAUTION: ^ Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and adjoining differential housing surface can occur if a floor jack or any lifting device is allowed to contact the cover at any point where the cover joins the housing. ^ Damage to the suspension, fuel tank, exhaust or steering linkage components can occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System Variable Valve Timing Actuator: Description and Operation Variable Cam Timing System Overview The Variable Cam Timing System allows the exhaust cam to advance and retard at varying engine speeds. The purpose of this is to reduce exhaust emissions and increase fuel economy. As the exhaust cam retards in relation to the crankshaft position, residual exhaust gases are left in the combustion chamber. The residual gases cool the combustion chamber and are inert when mixed with the incoming fresh charge of fuel and air. This results in better fuel economy and lower Nitrogen Oxides (NOx) and Hydrocarbons (HC) the engine produces. The Exhaust Gas Recalculation System (EGR) is unnecessary on the 2.0L (4V) engine due to this feature. Variable Cam Timing Variable Cam Timing System The Variable Cam Timing (VCT) System consists of the control solenoid, five-tooth pulse ring (4+1) on exhaust camshaft, Intake Air Temperature (IAT) sensor, Engine Coolant Temperature (ECT) sensor, Camshaft Position (CMP) sensor, Mass Air Flow (MAF) sensor, Crankshaft Position (CKP) sensor, Powertrain Control Module (PCM) (Figure 127). 1. The powertrain control module (PCM) receives input signals from the intake air temperature (IAT) sensor, engine coolant temperature (ECT) sensor, camshaft position (CMP) sensor, mass air flow (MAF) sensor and crankshaft position (CKP) sensor for determining the operating conditions of the engine. 2. The Variable Cam Timing (VCT) system is enabled by the PCM when the proper conditions are met. The PCM disables the VCT system if a fault is detected. 3. The PCM calculates relative cam position using the CMP sensor and data from the (4+1) pulse ring mounted on the exhaust camshaft. Relative cam position is calculated by measuring the time between the rising edge of Profile Ignition Pickup (PIP) and the falling edge of VCT pulse. 4. The PCM continually calculates a cam position error value based on the difference between the desired and actual position and a duty cycle is commanded for the VCT solenoid valve. Engine oil is allowed to flow to the VCT unit. 5. Oil flows to either side of the piston chamber changing a linear motion from the piston to a rotation motion from the helical mechanism in the VCT unit. During closed loop the PCM outputs a revised duty cycle to the VCT solenoid valve to correct for cam position error. Hardware Variable Cam Timing (VCT) Solenoid Valve Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System > Page 2458 Variable Cam Timing (VCT) Solenoid Valve The VCT solenoid valve (Figure 128) is an integral part of the VCT system. The solenoid valve controls the flow of engine oil to the variable cam timing unit assembly. As the PCM duty cycles the solenoid valve, oil is allowed to flow to the VCT unit assembly and advance or retard the cam timing. Variable Cam Timing (VCT) Unit Assembly Variable Cam Timing Unit Assembly The variable cam timing unit assembly (Figure 129) is coupled to the camshaft through a helical spline in the VCT unit chamber. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the piston to move linearly along the axis of the camshaft. This linear motion is translated into rotational camshaft motion through the helical spline coupling. A spring installed in the chamber is designed to hold the camshaft in the minimum overlap position (5 degrees) when oil pressure is too low to maintain adequate position control. The camshaft is allowed to rotate up to 30 degrees. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System > Page 2459 Variable Valve Timing Actuator: Description and Operation Variable Cam Timing (VCT) Unit Assembly Variable Cam Timing (VCT) Unit Assembly Variable Cam Timing Unit Assembly The variable cam timing unit assembly (Figure 129) is coupled to the camshaft through a helical spline in the VCT unit chamber. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the piston to move linearly along the axis of the camshaft. This linear motion is translated into rotational camshaft motion through the helical spline coupling. A spring installed in the chamber is designed to hold the camshaft in the minimum overlap position (5 degrees) when oil pressure is too low to maintain adequate position control. The camshaft is allowed to rotate up to 30 degrees. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Description and Operation Variable Valve Timing Solenoid: Description and Operation Variable Cam Timing (VCT) Solenoid Valve Variable Cam Timing (VCT) Solenoid Valve The VCT solenoid valve (Figure 128) is an integral part of the VCT system. The solenoid valve controls the flow of engine oil to the variable cam timing unit assembly. As the PCM duty cycles the solenoid valve, oil is allowed to flow to the VCT unit assembly and advance or retard the cam timing. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications Compression Pressure Limit Chart The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 2466 Compression Check: Testing and Inspection Compression Test-Compression Gauge Check 1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level and that the battery is correctly charged. Operate the vehicle until the engine is at normal operating temperature. Turn the ignition switch to the OFF position, then remove all the spark plugs. 2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the Compression Tester in the No. 1 cylinder. 4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position, and using the auxiliary starter switch, crank the engine a minimum of five compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Compression Test-Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Compression Test-Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. 2. If compression does not improve, valves are sticking or seating incorrectly. 3. If two adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 2467 Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is within 75 percent of the highest reading. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications Camshaft Bearing: Specifications CAMSHAFT BEARING CAP BOLTS Refer to procedure Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Camshaft Sprocket Bolt ....................................................................................................................... .................................................... 85 Nm (63 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications Camshaft: Specifications Camshaft Bearing Cap Bolts ............................................................................................................... .................................................... Refer to procedure Hydraulic Camshaft Tensioner ........................ ........................................................................................................................................ Refer to procedure Camshaft Theoretical valve lift @ 0 lash ............................................................................................................. .......................................................................... TBD Lobe lift intake mm (inch) ................................. ............................................................................................................................................... 6.584 (0.259) Lobe lift exhaust mm (inch) ..................................................................................................... ......................................................................... 6.584 (0.259) Allowable lobe lift loss mm (inch) ........ ............................................................................................................................................................ 0.127(0.003) Journal diameter mm (inch) ....................................................................................................................................................... 27.935-27.96 (1.099-1.101) Journal bore inside diameter mm (inch) ......................................................................................................................................... 28.0-28.03 (1.102-1.104) Journal to bearing clearance mm (inch) ......................................................................................................................................... 0.04-0.095 (0.002-0.004) Runout mm (inch) ......................................................................................................... ...................................................................................... 0.05 (0.002) End play mm (inch) .................. .................................................................................................................................................. 0.075-0.185 (0.0003-0.007) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft-LH Camshaft: Service and Repair Camshaft-LH NOTE: Ford does not provide timing marks or additional information for servicing of the timing chains/sprockets without the special tools listed in this procedure. Camshaft-LH Removal 1. Remove the camshaft roller followers. 2. Remove the LH hydraulic camshaft tensioner. 3. Remove the bolt and the camshaft sprocket. 4. NOTE: Mark the position of the camshaft bearing caps so they can be installed in the original position. Remove the bolts in the sequence shown and remove the camshaft bearing caps and the oil supply tube. 5. Remove the camshaft. Installation Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft-LH > Page 2480 1. NOTE: Lubricate the parts with clean engine oil before installing. Install the camshaft. 2. NOTE: The camshaft bearing caps must be installed in the original position. NOTE: After installing the bolts, check the camshaft for free rotation. Position the oil supply tube, the camshaft bearing caps, and the bolts. ^ Tighten the bolts in the sequence shown in two stages. ^ Stage 1: Tighten the bolts to 6 Nm (53 inch lbs.). ^ Stage 2: Tighten the bolts to 16 Nm (12 ft. lbs.). 3. The camshaft must be retimed. 4. Install the camshaft roller followers. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft-LH > Page 2481 Camshaft: Service and Repair Camshaft-RH NOTE: Ford does not provide timing marks or additional information for servicing of the timing chains/sprockets without the special tools listed in this procedure. Camshaft-RH Special Tool(s) Removal 1. Remove the camshaft roller followers. 2. Remove the RH hydraulic camshaft tensioner. 3. CAUTION: The right-hand camshaft sprocket bolt is a left-hand threaded bolt. Using the special tool, remove the bolt and the camshaft sprocket. 4. NOTE: Mark the position of the camshaft bearing caps so they can be installed in the original position. Remove the bolts in the sequence shown and remove the camshaft bearing caps and the oil supply tube. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft-LH > Page 2482 5. Remove the camshaft. Installation 1. NOTE: Lubricate the parts with clean engine oil before installing. Install the camshaft. 2. NOTE: The camshaft bearing caps must be installed in their original position. NOTE: After installing the bolts, check the camshaft for free rotation. Position the oil supply tube, the camshaft bearing caps, and the bolts. ^ Tighten the bolts in the sequence shown in two stages: ^ Stage 1: Tighten the bolts to 6 Nm (53 inch lbs.). ^ Stage 2: Tighten the bolts to 16 Nm (12 ft. lbs.). 3. The camshaft must be re-timed. 4. Install the camshaft roller followers. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Specifications Lifter / Lash Adjuster: Specifications Theoretical valve lift @ 0 lash ............................................................................................................. .......................................................................... TBD Lobe lift intake mm (inch) ................................. ............................................................................................................................................... 6.584 (0.259) Lobe lift exhaust mm (inch) ..................................................................................................... ......................................................................... 6.584 (0.259) Allowable lobe lift loss mm (inch) ........ ............................................................................................................................................................ 0.127(0.003) Journal diameter mm (inch) ....................................................................................................................................................... 27.935-27.96 (1.099-1.101) Journal bore inside diameter mm (inch) ......................................................................................................................................... 28.0-28.03 (1.102-1.104) Journal to bearing clearance mm (inch) ......................................................................................................................................... 0.04-0.095 (0.002-0.004) Runout mm (inch) ......................................................................................................... ...................................................................................... 0.05 (0.002) End play mm (inch) .................. .................................................................................................................................................. 0.075-0.185 (0.0003-0.007) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Specifications > Page 2486 Lifter / Lash Adjuster: Service and Repair Hydraulic Lash Adjusters Removal and Installation 1. Remove the camshaft roller followers. 2. Remove the hydraulic lash adjusters. 3. NOTE: Lubricate the parts with clean engine oil prior to installing. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Roller follower ratio .............................................................................................................................. ......................................................................... TBD Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 2490 Rocker Arm Assembly: Service and Repair Roller Followers Special Tool(s) Removal 1. Remove the valve covers. 2. Remove the fuel supply manifold. 3. NOTE: Mark each camshaft roller follower to ensure its original position during reassembly. Using the special tool, remove the camshaft roller followers. 4. NOTE: Lubricate the parts with clean engine oil prior to installing. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System Variable Valve Timing Actuator: Description and Operation Variable Cam Timing System Overview The Variable Cam Timing System allows the exhaust cam to advance and retard at varying engine speeds. The purpose of this is to reduce exhaust emissions and increase fuel economy. As the exhaust cam retards in relation to the crankshaft position, residual exhaust gases are left in the combustion chamber. The residual gases cool the combustion chamber and are inert when mixed with the incoming fresh charge of fuel and air. This results in better fuel economy and lower Nitrogen Oxides (NOx) and Hydrocarbons (HC) the engine produces. The Exhaust Gas Recalculation System (EGR) is unnecessary on the 2.0L (4V) engine due to this feature. Variable Cam Timing Variable Cam Timing System The Variable Cam Timing (VCT) System consists of the control solenoid, five-tooth pulse ring (4+1) on exhaust camshaft, Intake Air Temperature (IAT) sensor, Engine Coolant Temperature (ECT) sensor, Camshaft Position (CMP) sensor, Mass Air Flow (MAF) sensor, Crankshaft Position (CKP) sensor, Powertrain Control Module (PCM) (Figure 127). 1. The powertrain control module (PCM) receives input signals from the intake air temperature (IAT) sensor, engine coolant temperature (ECT) sensor, camshaft position (CMP) sensor, mass air flow (MAF) sensor and crankshaft position (CKP) sensor for determining the operating conditions of the engine. 2. The Variable Cam Timing (VCT) system is enabled by the PCM when the proper conditions are met. The PCM disables the VCT system if a fault is detected. 3. The PCM calculates relative cam position using the CMP sensor and data from the (4+1) pulse ring mounted on the exhaust camshaft. Relative cam position is calculated by measuring the time between the rising edge of Profile Ignition Pickup (PIP) and the falling edge of VCT pulse. 4. The PCM continually calculates a cam position error value based on the difference between the desired and actual position and a duty cycle is commanded for the VCT solenoid valve. Engine oil is allowed to flow to the VCT unit. 5. Oil flows to either side of the piston chamber changing a linear motion from the piston to a rotation motion from the helical mechanism in the VCT unit. During closed loop the PCM outputs a revised duty cycle to the VCT solenoid valve to correct for cam position error. Hardware Variable Cam Timing (VCT) Solenoid Valve Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System > Page 2495 Variable Cam Timing (VCT) Solenoid Valve The VCT solenoid valve (Figure 128) is an integral part of the VCT system. The solenoid valve controls the flow of engine oil to the variable cam timing unit assembly. As the PCM duty cycles the solenoid valve, oil is allowed to flow to the VCT unit assembly and advance or retard the cam timing. Variable Cam Timing (VCT) Unit Assembly Variable Cam Timing Unit Assembly The variable cam timing unit assembly (Figure 129) is coupled to the camshaft through a helical spline in the VCT unit chamber. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the piston to move linearly along the axis of the camshaft. This linear motion is translated into rotational camshaft motion through the helical spline coupling. A spring installed in the chamber is designed to hold the camshaft in the minimum overlap position (5 degrees) when oil pressure is too low to maintain adequate position control. The camshaft is allowed to rotate up to 30 degrees. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System > Page 2496 Variable Valve Timing Actuator: Description and Operation Variable Cam Timing (VCT) Unit Assembly Variable Cam Timing (VCT) Unit Assembly Variable Cam Timing Unit Assembly The variable cam timing unit assembly (Figure 129) is coupled to the camshaft through a helical spline in the VCT unit chamber. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the piston to move linearly along the axis of the camshaft. This linear motion is translated into rotational camshaft motion through the helical spline coupling. A spring installed in the chamber is designed to hold the camshaft in the minimum overlap position (5 degrees) when oil pressure is too low to maintain adequate position control. The camshaft is allowed to rotate up to 30 degrees. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft > Component Information > Specifications Balance Shaft: Specifications Balance shaft bolts .............................................................................................................................. ........................................... 26-28 Nm (19-21 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft Belt Tensioner > Component Information > Specifications Balance Shaft Belt Tensioner: Specifications Balance shaft tensioner bolts .......................................................................................................................................................... 28-30 Nm (21-22 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft Chain Guide > Component Information > Specifications Balance Shaft Chain Guide: Specifications Balance shaft chain guide ............................................................................................................................................................ 9-11 Nm (80-97 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications Connecting rod journal diameter mm (inch) .................................................................................................................................. 53.98-54.0 (2.125-2.126) Connecting rod journal maximum taper mm (inch) ........................................................................................................................................ 0.008 (0.0003) Connecting rod journal maximum out-of-round mm (inch) ............................................................................................................................ 0.008 (0.0003) Connecting rod pin bore diameter mm (inch) .......................................................................................................................... 23.958-23.976 (0.943-0.944) Connecting rod length mm (inch) ....................................................................................................................................... 145.965146.035 (5.746-5.749) Connecting rod maximum allowed bend mm (inch) ........................................ ........................................................................................................................................... 0.0125 (0.00049) per 25.4 mm (1.000) Connecting rod maximum allowed twist mm (inch) ........................... ............................................................................................................................................................ 0.038 (0.0015) per 25.4 mm (1.000) Connecting rod bearing bore diameter mm (inch) ..................... .............................................................................................................................................................. ............................. 56.82-56.84 (2.237) Connecting rod bearing-to-crankshaft clearance mm (inch) . .............................................................................................................................................................. ....................................... 0.013-0.048 (0.005-0.002) Connecting rod side clearance (assembled to crankshaft) mm (inch) .......................................................................................................................... ........................................................................ 0.092-0.268 (0.0036-0.0106) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications Connecting Rod: Specifications Connecting Rod Bolts .......................................................................................................................... ................................................... Refer to procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications Crankshaft Main Bearing: Specifications Main bearing cap bolts ........................................................................................................................ ..................................................... 97 Nm (72 ft. lbs.) Crankshaft Main bearing journal diameter mm (inch) ................................................................................................................................... 56.980-57.0 (2.243-2.244) Main bearing journal maximum taper mm (inch) ........................................................................................................................................... 0.008 (0.0003) Main bearing journal maximum out-of-round mm (inch) ............................................................................................................................... 0.008 (0.0003) Main bearing journal-to-cylinder block clearance mm (inch) ........................................................................................................................................ TBD Connecting rod journal diameter mm (inch) .................................................................................................................................. 53.98-54.0 (2.125-2.126) Connecting rod journal maximum taper mm (inch) ........................................................................................................................................ 0.008 (0.0003) Connecting rod journal maximum out-of-round mm (inch) ............................................................................................................................ 0.008 (0.0003) Crankshaft maximum end play mm (inch) ..................................................................................................................................... 0.05-0.32 (0.002-0.0126) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications Jackshaft chain guide bolts ................................................................................................................. ...................................................... 19 Nm (14 ft. lbs.) Jackshaft chain tensioner bolts ....................... ......................................................................................................................................... 9 Nm (80 inch lbs.) Jackshaft thrust plate bolts ................................................................................................... ................................................................... 11 Nm (8 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Specifications Engine Block Heater: Specifications Heater hose bracket bolts .................................................................................................................... ...................................................... 23 Nm (17 ft. lbs.) Block heater screw .......................................... ............................................................................................................................................ 2 Nm (18 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Specifications > Page 2522 Engine Block Heater: Service and Repair Block Heater Removal and Installation 1. Drain the cooling system. 2. Raise the vehicle. 3. Disconnect the block heater power cable from the block heater. 4. CAUTION: Do not loosen the block heater retaining screw more than necessary for removal. Remove the block heater. 5. CAUTION: Make sure the power cable is routed and secured away from rotating or hot components or damage to the cable may occur. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft Pulley Bolts ....................................................................................................................... ................................................... Refer to procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2526 Harmonic Balancer - Crankshaft Pulley: Service and Repair Crankshaft Pulley Special Tools Special Tool(s) Removal 1. Remove the fan shroud. 2. Remove the accessory drive belt. 3. CAUTION: This bolt is torque to yield and cannot be reused. Remove the damper bolt. 4. Using the special tool, remove the crankshaft pulley. Installation Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2527 1. Using the special tool, install the crankshaft pulley. 2. Install a new crankshaft pulley bolt. ^ Tighten the bolt in two stages: ^ Stage l: Tighten the bolt to 50 Nm (37 ft. lbs.). ^ Stage 2: Tighten the bolt an additional 90 degrees. 3. Install the accessory drive belt. 4. Install the fan shroud. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Piston and Connecting Rod Piston diameter-coded STD mm (inch) .............................................................................................................................. 100.380-100.400 (3.952-3.9528) Piston diameter-coded 0.5 mm (inch) ............................................................................................................................................ 100.880-100.900 (3.972) Piston diameter-coded 1.0 mm (inch) ................................................................................................................................. 101.350-101.370 (3 990-3.991) Piston-to-cylinder bore clearance mm (inch) ............................................................................................................................. 0.030-0.060 (0.0012-0.002) Piston top ring end gap mm (inch) ............................................................................................................................................... 0.200-0.450 (0.008-0.018) Piston bottom ring end gap mm (inch) ......................................................................................................................................... 0.450-0.700 (0.018-0.028) Piston top ring groove width mm (inch) ...................................................................................................................................... 1.64-1.66 (0.0645-0.0654) Piston bottom ring groove width mm (inch) ................................................................................................................................ 1.79-1.81 (0.0705-0.0713) Piston oil ring groove width mm (inch) ......................................................................................................................................... 3.5-3.53 (O.1378-0.1399) Piston top ring width mm (inch) .................................................................................................................................................. 1.578-1.598 (0.062-0.063) Piston bottom ring width mm (inch) ............................................................................................................................................... 1.728-1.74(0.068-0.069) Piston top ring-to-groove clearance mm (inch) .......................................................................................................................... 0.050-0.082 (0.002-0.0003) Piston bottom ring-to-groove clearance mm (inch) ...................................................................................................................... 0.050-0.082 (0.002-0.003) Piston pin bore diameter (red) mm (inch) .......................................................................................................................................... 24.007-24.010 (0.945) Piston pin bore diameter (blue) mm (inch) ......................................................................................................................................... 24.010-24.013 (0.945) Piston pin diameter (red) mm (inch) .................................................................................................................................... 23.994-23.997 (0.9446-0.9447) Piston pin diameter (blue) mm (inch) .................................................................................................................................. 23.997-24.000 (0.9447-0.9449) Piston pin length mm (inch) ............................................................................................................................................................. 72.0-72.8 (2.835-2.866) Piston pin-to-piston pin fit mm (inch) ........................................................................................................................................ 0.01-0.016 (0.0004-0.0006) Piston pin-to-connecting rod clearance mm (inch) ..................................................................................... Press Fit -0.018 to -0.042 (-0.0007 to -.0017) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications Piston Pin: Specifications Piston pin bore diameter (red) mm (inch) .......................................................................................................................................... 24.007-24.010 (0.945) Piston pin bore diameter (blue) mm (inch) ......................................................................................................................................... 24.010-24.013 (0.945) Piston pin diameter (red) mm (inch) .................................................................................................................................... 23.994-23.997 (0.9446-0.9447) Piston pin diameter (blue) mm (inch) .................................................................................................................................. 23.997-24.000 (0.9447-0.9449) Piston pin length mm (inch) ............................................................................................................................................................. 72.0-72.8 (2.835-2.866) Piston pin-to-piston pin fit mm (inch) ........................................................................................................................................ 0.01-0.016 (0.0004-0.0006) Piston pin-to-connecting rod clearance mm (inch) ..................................................................................... Press Fit -0.018 to -0.042 (-0.0007 to -.0017) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Piston top ring end gap mm (inch) ............................................................................................................................................... 0.200-0.450 (0.008-0.018) Piston bottom ring end gap mm (inch) ......................................................................................................................................... 0.450-0.700 (0.018-0.028) Piston top ring groove width mm (inch) ...................................................................................................................................... 1.64-1.66 (0.0645-0.0654) Piston bottom ring groove width mm (inch) ................................................................................................................................ 1.79-1.81 (0.0705-0.0713) Piston oil ring groove width mm (inch) ......................................................................................................................................... 3.5-3.53 (O.1378-0.1399) Piston top ring width mm (inch) .................................................................................................................................................. 1.578-1.598 (0.062-0.063) Piston bottom ring width mm (inch) ............................................................................................................................................... 1.728-1.74(0.068-0.069) Piston top ring-to-groove clearance mm (inch) .......................................................................................................................... 0.050-0.082 (0.002-0.0003) Piston bottom ring-to-groove clearance mm (inch) ...................................................................................................................... 0.050-0.082 (0.002-0.003) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions > Page 2541 Fuel Pressure Release: Service and Repair Fuel Pressure Gauge SPECIAL TOOL(S) WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Disconnect the battery ground cable. 2. Remove the Schrader valve cap and attach the Fuel Pressure Gauge. 3. Open the manual valve on the Fuel Pressure Gauge slowly to relieve the fuel system pressure. This may drain fuel from the system. Drain the fuel into a suitable container. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions > Page 2542 Fuel Pressure Gauge Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Roller follower ratio .............................................................................................................................. ......................................................................... TBD Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 2546 Rocker Arm Assembly: Service and Repair Roller Followers Special Tool(s) Removal 1. Remove the valve covers. 2. Remove the fuel supply manifold. 3. NOTE: Mark each camshaft roller follower to ensure its original position during reassembly. Using the special tool, remove the camshaft roller followers. 4. NOTE: Lubricate the parts with clean engine oil prior to installing. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications Valve Cover: Specifications Valve Cover bolts ................................................................................................................................ ................................................... 10Nm (89 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover-RH Valve Cover: Service and Repair Valve Cover-RH Valve Cover-RH Removal and Installation 1. Drain the cooling system. 2. Remove the air cleaner outlet pipe. ^ Disconnect the tube. ^ Detach the Mass Airflow (MAF) sensor wiring pushpin. ^ Loosen the clamps and remove the pipe. 3. Release hose clamps and remove hose. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover-RH > Page 2552 4. Remove hose. 5. Disconnect the vacuum hose. 6. Loosen hose clamps and disconnect hoses. 7. Release hose clamps and disconnect hoses. 8. Release hose clamp and disconnect hose. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover-RH > Page 2553 9. Release hose clamp and disconnect hose. Position hose aside. 10. Remove the bolts. 11. Detach the wiring harness retainer. ^ Remove the heater tube and bracket assembly. 12. Disconnect MAF sensor connector and wiring pushpin. Position wiring aside. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover-RH > Page 2554 13. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug wire locations before removing them. Position the spark plug wires aside. 1 Disconnect the spark plug wires. 2 Disconnect the spark plug wire retainer and position the wires aside. 14. Disconnect fuel injector connectors. Position wiring aside. 15. Remove the bolts and the valve cover. 16. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover-RH > Page 2555 Valve Cover: Service and Repair Valve Cover-LH Valve Cover-LH Special Tool(s) Removal and Installation 1. Disconnect the battery negative cable. 2. Detach the accelerator and speed control cables. 1 Detach the accelerator and speed control cables from the throttle body. 2 Detach the accelerator and speed control cables from the bracket, and position the cables aside. 3. Detach the spark plug wire retainer. 4. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug wire locations before removing them. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover-RH > Page 2556 Disconnect the spark plug wires. 5. Remove the bolts. 6. Remove the bolt. 7. Disconnect the coil electrical connector. 8. Disconnect the radio interference capacitor electrical connector and position the coil aside. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover-RH > Page 2557 9. Loosen the bolt and disconnect the electrical connector. 10. Disconnect the following: 1 Exhaust Gas Recirculation (EGR) valve vacuum hose. 2 EGR valve vacuum regulator solenoid vacuum hoses. 3 EGR valve vacuum regulator solenoid electrical connector. 4 Camshaft position sensor electrical connector. ^ Differential pressure feedback electrical connector. 11. Detach the spark plug wire retainer. 12. Disconnect the fuel vapor hose and the vacuum hose. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover-RH > Page 2558 13. Remove the bolt and position the electrical connector and bracket aside. 14. Remove the screws and the EGR valve vacuum regulator solenoid. 15. Remove the differential pressure feedback with the hoses from the exhaust manifold-to-EGR valve tube. 16. Relieve the fuel system pressure. 17. Detach the clip. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover-RH > Page 2559 18. Using the special tool, disconnect the fuel supply line. 19. Remove the bolt and position the fuel supply line aside. 20. Loosen the fitting and disconnect the exhaust manifold-to-EGR valve tube. 21. Disconnect the hose. 22. Unscrew fitting. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover-RH > Page 2560 23. Remove the bolts and the valve cover. 24. To install. reverse removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications Valve Guide: Specifications Valve guide bore diameter mm (inch) ...................................................................................................................................................... 7.00-7.018 (0.276) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications Valve Seat: Specifications Valve seat width (exhaust and intake) mm (inch) ................................................................................ ............................................................................... 1.556-2.404 (0.06-0.094) 1.273-2.121 (0.05-0.083) Valve seat runout (TIR maximum) mm (inch) .................................................................................................................................................. 0.059 (0.002) Valve seat angle (degrees) ..................................................................................................... ............................................................................... 45 degrees Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Technical Service Bulletins > Customer Interest for Valve Spring: > 02-3-2 > Feb > 02 > Engine Control - MIL ON, DTC P0300 or P0301 Set Valve Spring: Customer Interest Engine Control - MIL ON, DTC P0300 or P0301 Set Article No. 02-3-2 02/18/02 ^ DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC) P0300/P0301 STORED IN MEMORY - VEHICLES EQUIPPED WITH 4.0L SOHC ENGINE ONLY ^ ELECTRICAL - LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED DIAGNOSTIC TROUBLE CODES (DTC) P0300/P0301 STORED IN MEMORY - VEHICLES EQUIPPED WITH 4.0L SOHC ENGINE ONLY ^ ENGINE - 4.0L SOHC - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED DIAGNOSTIC TROUBLE CODES (DTC) P0300/P0301 STORED IN MEMORY - VEHICLES EQUIPPED WITH 4.0L SOHC ENGINE ONLY FORD: 1997-2002 EXPLORER SPORT, EXPLORER 2001-2002 EXPLORER SPORT TRAC, RANGER MERCURY: 1997-2002 MOUNTAINEER ISSUE Some vehicles equipped with the 4.0L SOHC engine may exhibit a CHECK ENGINE LIGHT "ON" with Diagnostic Trouble Codes (DTC) P0300 (Random Misfire) or P0301. The DTC will set when the engine is operated at high RPM'S (4800 RPM and higher). The Misfire code results due to system interaction of higher than expected transient exhaust system backpressure (under heavy acceleration) coupled with valve spring resonance points experienced at these engine speeds. This interaction may cause the' exhaust valve to hang open at engine speeds of 4800 RPM and higher. ACTION Verify that the DTC sets only at 4800 RPM or higher. Remove current intake and exhaust valve springs and replace with new service intake and exhaust valve springs. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE THIS REPAIR ONLY APPLIES TO P0300/P0301 DTC'S SET ABOVE 4800 RPM. THIS REPAIR WILL NOT CORRECT MISFIRE DTC'S SET AT LOWER RPM'S. NOTE PRIOR TO REPAIR, REFERENCE YOUR APPLICABLE WORKSHOP MANUAL FOR CORRECT VALVE SPRING REMOVAL/REPLACEMENT PROCEDURES. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Technical Service Bulletins > Customer Interest for Valve Spring: > 02-3-2 > Feb > 02 > Engine Control - MIL ON, DTC P0300 or P0301 Set > Page 2575 1. Gain access to the valve springs. 2. Remove (quantity 12) existing intake and exhaust valve springs F77Z-6513-M and replace with new service intake and exhaust valve springs 2L2Z-6513-AA. NOTE ALL "12" VALVE SPRINGS ("6" INTAKE AND "6" EXHAUST) MUST BE REPLACED IN ORDER TO MAINTAIN/ENSURE PROPER VALVETRAIN DYNAMICS. 3. Road test vehicle to verify repair. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 6513 42 OASIS CODES: 499000, 608000, 609000, 6100000, 611000, 611500, 698298 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Spring: > 02-3-2 > Feb > 02 > Engine Control - MIL ON, DTC P0300 or P0301 Set Valve Spring: All Technical Service Bulletins Engine Control - MIL ON, DTC P0300 or P0301 Set Article No. 02-3-2 02/18/02 ^ DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC) P0300/P0301 STORED IN MEMORY - VEHICLES EQUIPPED WITH 4.0L SOHC ENGINE ONLY ^ ELECTRICAL - LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED DIAGNOSTIC TROUBLE CODES (DTC) P0300/P0301 STORED IN MEMORY - VEHICLES EQUIPPED WITH 4.0L SOHC ENGINE ONLY ^ ENGINE - 4.0L SOHC - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED DIAGNOSTIC TROUBLE CODES (DTC) P0300/P0301 STORED IN MEMORY - VEHICLES EQUIPPED WITH 4.0L SOHC ENGINE ONLY FORD: 1997-2002 EXPLORER SPORT, EXPLORER 2001-2002 EXPLORER SPORT TRAC, RANGER MERCURY: 1997-2002 MOUNTAINEER ISSUE Some vehicles equipped with the 4.0L SOHC engine may exhibit a CHECK ENGINE LIGHT "ON" with Diagnostic Trouble Codes (DTC) P0300 (Random Misfire) or P0301. The DTC will set when the engine is operated at high RPM'S (4800 RPM and higher). The Misfire code results due to system interaction of higher than expected transient exhaust system backpressure (under heavy acceleration) coupled with valve spring resonance points experienced at these engine speeds. This interaction may cause the' exhaust valve to hang open at engine speeds of 4800 RPM and higher. ACTION Verify that the DTC sets only at 4800 RPM or higher. Remove current intake and exhaust valve springs and replace with new service intake and exhaust valve springs. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE THIS REPAIR ONLY APPLIES TO P0300/P0301 DTC'S SET ABOVE 4800 RPM. THIS REPAIR WILL NOT CORRECT MISFIRE DTC'S SET AT LOWER RPM'S. NOTE PRIOR TO REPAIR, REFERENCE YOUR APPLICABLE WORKSHOP MANUAL FOR CORRECT VALVE SPRING REMOVAL/REPLACEMENT PROCEDURES. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Spring: > 02-3-2 > Feb > 02 > Engine Control - MIL ON, DTC P0300 or P0301 Set > Page 2581 1. Gain access to the valve springs. 2. Remove (quantity 12) existing intake and exhaust valve springs F77Z-6513-M and replace with new service intake and exhaust valve springs 2L2Z-6513-AA. NOTE ALL "12" VALVE SPRINGS ("6" INTAKE AND "6" EXHAUST) MUST BE REPLACED IN ORDER TO MAINTAIN/ENSURE PROPER VALVETRAIN DYNAMICS. 3. Road test vehicle to verify repair. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 6513 42 OASIS CODES: 499000, 608000, 609000, 6100000, 611000, 611500, 698298 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Technical Service Bulletins > Page 2582 Valve Spring: Specifications Valve spring free length intake mm (inch) ............................................................................................................................................................. 43.1 (1.7) Valve spring free length exhaust mm (inch) ........................................................................................................................................................... 43.1 (1.7) Valve spring squareness ..................................................................................................... ............................................................................................ TBD Valve spring compression pressure intake at (specified height) (lb) ............... 275-305 Nm at 35.9-36.7 mm (202.84-224.968 ft. lbs. at 1.413-1.445 inch) Valve spring compression pressure exhaust (at specified height) (lb) ............ 275-305 Nm at 35.9-36.7 mm (202.84-224.968 ft. lbs. at 1.413-1.445 inch) Valve spring installed height intake mm (inch) ............................................................................................................................ 39.86-40.86 (1.569-1.601) Valve spring installed height exhaust mm (inch) ......................................................................................................................... 39.86-40.68 (1.569-1.601) Valve spring installed pressure ..................................................................................... .................................................................................................. TBD Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Technical Service Bulletins > Page 2583 Valve Spring: Service and Repair Valve-Valve Spring Special Tool(s) Removal and Installation 1. Remove the camshaft roller followers. 2. Position the piston at top dead center. 3. Hold the valve in the cylinder head. ^ Remove the spark plugs. ^ Use a suitable tool to apply air pressure to the cylinder. 4. CAUTION: If air pressure has forced the piston to the bottom of the cylinder, any loss of air pressure will allow the valve to fall into the cylinder. If air pressure must be removed, support the valve prior to removal. Using the special tool, remove the valve spring retainer keys, the valve spring and the retainer. 5. Inspect the components. 6. NOTE: Lubricate the parts with clean engine oil prior to installing. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications Valve: Specifications Valve arrangement (front to rear) ...................................................................................................................................... LH-I-E-I-E-I-E (RH-E-I-E-I-E-I) Valve guide bore diameter mm (inch) ...................................................................................................................................................... 7.00-7.018 (0.276) Valve stem diameter intake mm (inch) .......................................................................................................................................... 6.965-6.98 (0.274-0.275) Valve stem diameter exhaust mm (inch) .................................................................................................................................................. 6.95-6.965 (0.274) Valve stem-to-guide clearance exhaust mm (inch) ....................................................................................................................... 0.035-0.068 (0.001-0.003) Valve stem-to-guide clearance intake mm (inch) ......................................................................................................................... 0.020-0.053 (0.001-0.002) Valve head diameter intake mm (inch) ............................................................................................................................................ 45.9-46.1 (1.807-1.815) Valve head diameter exhaust mm (inch) ........................................................................................................................................ 38.9-39.1 (1.531 - 1.539) Valve face runout ........................................................................................................ ....................................................................................... 0.03 (0.001) Valve face angle (degrees) ..... .............................................................................................................................................................. ................. 45 degrees Valve seat width (exhaust and intake) mm (inch) ........................................... .................................................................................................................... 1.556-2.404 (0.06-0.094) 1.273-2.121 (0.05-0.083) Valve seat runout (TIR maximum) mm (inch) .................................................................................................................................................. 0.059 (0.002) Valve seat angle (degrees) ..................................................................................................... ............................................................................... 45 degrees Valve spring free length intake mm (inch) ............................................................................................................................................................. 43.1 (1.7) Valve spring free length exhaust mm (inch) ........................................................................................................................................................... 43.1 (1.7) Valve spring squareness ..................................................................................................... ............................................................................................ TBD Valve spring compression pressure intake at (specified height) (lb) ......................................................................................................................... 275-305 Nm at 35.9-36.7 mm (202.84-224.968 ft. lbs. at 1.413-1.445 inch) Valve spring compression pressure exhaust (at specified height) (lb) ......................................................................................................................... 275-305 Nm at 35.9-36.7 mm (202.84-224.968 ft. lbs. at 1.413-1.445 inch) Valve spring installed height intake mm (inch) ............................................................................................................................ 39.86-40.86 (1.569-1.601) Valve spring installed height exhaust mm (inch) ......................................................................................................................... 39.86-40.68 (1.569-1.601) Valve spring installed pressure ..................................................................................... .................................................................................................. TBD Roller follower ratio ................... .............................................................................................................................................................. ...................... TBD Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair Drive Belt: Service and Repair Accessory Drive Belt Removal and Installation 1. Remove the air cleaner outlet tube. 2. Remove the accessory drive belt. 1 Rotate the accessory drive belt tensioner counterclockwise. 2 Remove the belt. 3. NOTE: Refer to Component locations for correct drive belt routing. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications Drive Belt Tensioner: Specifications Drive belt tensioner bolt ....................................................................................................................... .................................................... 47 Nm (35 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Specifications Engine Accessory Bracket: Specifications Accessory bracket bolts ....................................................................................................................... ..................................................... 12 Nm (31 ft. lbs.) Engine lifting eye bolts ..................................... ....................................................................................................................................... 28 Nm (21 ft. lbs.) Lower engine mount bracket nuts ............................................................................................................................................................. 80 Nm (59 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Specifications Engine Mount: Specifications Upper engine mount bracket nuts ........................................................................................................................................................... 110 Nm (81 ft. lbs.) Lower engine mount bracket bolts ............................................................................................................................................................ 80 Nm (59 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Specifications > Page 2600 Engine Mount: Service and Repair Engine Support Insulators Removal and Installation All vehicles 1. Remove the fan shroud. 2. Remove the LH engine insulator nuts. 3. Remove the RH engine insulator nuts. 4. Raise and support the vehicle. 4x4 vehicles 5. Secure the axle housing to a suitable lift. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Specifications > Page 2601 6. Loosen, but do not remove, the front axle bolts. Position the lift to access the left motor mount nut. All vehicles 7. Remove the LH and RH engine support insulator nuts. 8. Raise and support the engine. 9. Remove the engine support insulators. 10. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Specifications Idler Pulley: Specifications Drive belt idler pulley bolt .................................................................................................................... .................................................... 47 Nm (35 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Minimum oil pressure at 2,000 rpm ............................................................................................................................................................. 103 kPa (15 psi) Note: engine at normal operating temperature. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Technical Service Bulletins > Engine - Oil Level Indicator Markings Engine Oil Dip Stick - Dip Stick Tube: Technical Service Bulletins Engine - Oil Level Indicator Markings Article No. 03-8-3 04/28/03 ENGINE - ENGINE OIL LEVEL INDICATOR MARKINGS - REPORTS OF LOW OIL LEVELS FORD: 2002 ESCORT 2002-2003 CROWN VICTORIA, ESCORT ZX2, FOCUS, MUSTANG, TAURUS, THUNDERBIRD, E SERIES, ESCAPE, EXCURSION, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, EXPLORER, F-150, RANGER, SUPER DUTY F SERIES, WINDSTAR LINCOLN: 2002 CONTINENTAL 2002-2003 LS, TOWN CAR, NAVIGATOR 2003 AVIATOR MERCURY: 2002-2003 COUGAR, GRAND MARQUIS, SABLE 2002 VILLAGER 2002-2003 MOUNTAINEER ISSUE Reports from the field indicate incorrect or low engine oil levels are being found at Pre-Delivery Inspection on new vehicles received in dealer inventory. In most cases, the level is being misinterpreted because the fluid fill mark on the stick is not touching the top hash mark at the upper limit (or MAX mark), or is partway down the crosshatch area. ACTION Ford is in the process of standardizing the markings across all vehicle lines. Current markings shown will be upgraded to a refined marking, shown in Figure 1. Both markings will be used in production over the next few years. Oil levels will still be recorded in the crosshatched area of the blade, between the upper and lower limit holes. Vehicles shipped with engine oil levels falling within this area are acceptable and do not require topping off. Oil fill quantities are precisely measured at the plants and account for slight variations that may occur in oil pan volumes, indicator length, and pressed-in locations of the indicator tube into the block. For customer use, the markings continue to serve as a guide to refilling the engine to the correct initial fill volume with filter or, to top off the engine when it is determined the level is below the lower hole. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Technical Service Bulletins > Engine - Oil Level Indicator Markings > Page 2613 SERVICE INFORMATION Ensure the vehicle is sitting on level ground. Set the park brake and ensure the transmission selector lever is in PARK position, or in FIRST gear on manuals. The engine must be OFF. The best time for determining oil level is before the engine is started and the oil has had sufficient drainback time to the sump. If the engine has been running, allow it to sit for a few minutes turned off. An oil drainback period is required before taking an initial reading. If the level falls below the lower hole, fill with one quart of oil. If one quart is insufficient to raise the level above the mark, add oil until it records within the crosshatch area. Use caution during this procedure as some time is needed for oil to drain down through the drainback passages in the cylinder head, to the oil pan. Adding oil a quart at a time repeatedly without sufficient drainback may overfill the sump. If the oil level falls between the upper and lower hole do not add more oil. Adding an extra quart could cause overfilling and may result in aeration (foaming) causing eventual damage to vital bearing surfaces and moving parts inside. Overfilling will require some oil to be drained out until the indicator shows the level between the upper and lower holes of the blade. DO NOT expect the engine to 'consume" the extra oil back down to the upper oil till level hole, or consider it as extra lubrication protection for the engine. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 490000, 499000 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Technical Service Bulletins > Page 2614 Engine Oil Dip Stick - Dip Stick Tube: Specifications Oil level indicator tube bracket bolt ......................................................................................................................................................... 25 Nm (18 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter............................................................................................................................................. ............................................................. 4.7L (5.0 Qt) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 2619 Engine Oil: Fluid Type Specifications Engine Oil ...................................................................................................................................... Super Premium SAE 5W30 Motor Oil XO-5W30-QSP Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Specifications Oil Filter: Specifications Oil bypass filter .................................................................................................................................... .................................................... 13 Nm (10 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Specifications Oil Filter Adapter: Specifications Oil filter adapter bolt ............................................................................................................................ .................................................... 57 Nm (42 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Oil pan bolts ......................................................................................................................................... ................................................... 9 Nm (80 inch lbs.) Oil pan drain plug ............................................. ........................................................................................................................................ 25 Nm (18 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2629 Oil Pan: Service and Repair Oil Pan Removal and Installation 1. Raise and support the vehicle. 2. Drain the engine oil. 3. Remove the bolts and the oil pan. 4. NOTE: All sealing surfaces must be cleaned prior to assembly. Use metal surface cleaner to clean the sealing surfaces. NOTE: Inspect integral oil pan gasket for cuts or damage that may cause leaks. Install a new gasket if necessary. NOTE: Fill the engine with clean engine oil. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams Connector View C103 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Specifications Oil Pick Up/Strainer: Specifications Oil pump screen cover and tube bolts .................................................................................................................................................. 10 Nm (89 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Minimum oil pressure at 2,000 rpm ............................................................................................................................................................. 103 kPa (15 psi) Note: engine at normal operating temperature. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications Intake Manifold: Specifications Intake manifold bolts ............................................................................................................................ ................................................ 10 Nm (89 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2643 Intake Manifold: Service and Repair Intake Manifold Removal and Installation 1. Disconnect the battery ground cable. 2. Remove the bolts and the shield. 3. Remove the air cleaner outlet pipe. ^ Disconnect the tube. ^ Detach the Mass Airflow (MAP) sensor wiring pushpin. ^ Loosen the clamps and remove the pipe. 4. Disconnect the Idle Air Control (IAC) valve and the Throttle Position Sensor (TPS) electrical connectors. Disconnect the Exhaust Gas Recirculation (EGR) valve vacuum hose. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2644 5. Disconnect the accelerator and speed control cables. 1 Detach the accelerator and speed control cables from the throttle body. 2 Detach the accelerator and speed control cables from the bracket, and position the cables aside. 6. Loosen the fitting and disconnect the exhaust manifold-to-EGR valve tube. 7. Disconnect the EGR valve vacuum regulator electrical connector and vacuum hoses. 8. Disconnect the hose. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2645 9. Loosen the clamp and disconnect the brake booster vacuum hose. 10. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug wire locations before removing them. Disconnect the RH spark plug wires from coil. Remove spark plug wire routing clip pushpin and position the wires aside. 11. Remove wiring harness bracket retainer, then position wiring harness aside. 12. Remove accelerator cable routing clip pushpin and wiring harness pushpin. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2646 13. Remove the bolts. 14. Remove the bolt and position the coil and bracket aside. 15. Disconnect the vacuum hoses. 16. Remove the nut. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2647 17. Disconnect the Powertrain Control Module (PCM) electrical connector. 18. Disconnect the ground wires and position the wiring harness aside. 19. Detach the electrical connector retainer. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2648 20. Remove the intake manifold bolts and lift up the intake manifold. 21. Remove the heated PCV hose retainers and remove the heated PCV fitting. 22. Remove the intake manifold. 23. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair Crankshaft Main Bearing Seal: Service and Repair Crankshaft Rear Oil Seal Special Tool(s) Removal 1. Remove the flexplate. 2. CAUTION: Avoid scratching or damaging the oil crankshaft seal running surface during removal of the crankshaft rear oil seal. Using the special tool, remove the crankshaft rear oil seal. Installation 1. NOTE: Be sure the crankshaft rear sealing surface is clean and free of any rust or corrosion. To clean the crankshaft rear sealing surface, use extra-fine emery cloth or extra-fine 0000 steel wool with metal surface cleaner. Lubricate the crankshaft rear oil seal with clean engine oil and install on the special tool. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Page 2653 2. Using the special tool, install the crankshaft rear oil seal. 3. Install the flexplate. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification Cylinder Head Gasket: Technical Service Bulletins Engine - Reman Engine Head Gasket Identification TSB 06-18-16 09/18/06 IDENTIFYING THE CORRECT REPLACEMENT HEAD GASKET FOR CERTAIN REMANUFACTURED ENGINES - SERVICE TIP FORD: 1999-2006 Mustang, Mustang, Mustang, Mustang, Mustang, Mustang 2000-2005 Thunderbird 2001-2005 Taurus 2001-2006 Crown Victoria, Crown Victoria 2005 Five Hundred, Freestyle 1997-2005 Expedition 1997-2006 E-Series, Explorer, F-150, F-Super Duty 1999-2003 Windstar 1999-2004 F-53 Motorhome Chassis 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Escape, Escape, Explorer Sport Trac, Ranger 2004-2005 Freestar, Freestar 2006 F-53 Motorhome Chassis LINCOLN: 2000-2006 Lincoln LS 2001-2002 Continental 2001-200 Town Car 1998-2004 Navigator, Navigator 2003-2004 Aviator 2006 Mark LT MERCURY: 2001 Cougar 2001-2005 Sable 2001-2006 Grand Marquis 2003-2006 Marauder 2005 Montego 1997-2006 Mountaineer 2004-2005 Monterey 2005 Mariner ISSUE On various vehicles when servicing the head gasket on certain Ford remanufactured engines, it is critical to determine the type of remanufactured engine that is being serviced, in order to identify the correct replacement gasket. ACTION Follow the Service Procedure to help identify if the vehicle is equipped with a SID (for originally equipment level thickness head gasket) or OVR (for oversized service level thicker head gasket) remanufactured engine when replacing a head gasket. SERVICE PROCEDURE Use this TSB to help identify if the vehicle is equipped with a STD or OVR remanufactured engine when replacing a head gasket. This will ensure that you obtain the proper head gasket (thicker for OVR-oversized) for the engine you are repairing, as the engine may have milled engine block deck, milled cylinder head deck, or an over sized bore in the cylinders. This information will be needed when ordering parts. The parts catalogs already reflect the correct service numbers, as long as this additional information is available. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 2658 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 2659 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 2660 For certain remanufactured engines, the long block assembly will be uniquely identified with a build date, reman code, service part number, and serial number. This metal tag will be marked with STD, or with OVR (Figures 1-6). WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 2661 Technical Service Bulletin # 02-1-4 Date: 020121 Engine Head Gasket - Approved Replacement Procedures Article No. 02-1-4 01/21/02 ENGINE - APPROVED HEAD GASKET REPLACEMENT SERVICE PROCEDURES FORD: 1992-1997 THUNDERBIRD 1992-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1995-2000 CONTOUR 2000-2002 FOCUS 1995-2002 WINDSTAR 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE LINCOLN: 1992-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1992-1997 COUGAR 1992-1999 TRACER 1992-2002 GRAND MARQUIS, SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER ISSUE Some engine assemblies with aluminum cylinder heads repaired in-vehicle have been found to leak coolant and/or oil from the cylinder head gasket area due to particle contamination or scratches and dents at the head to block mating surfaces. ACTION Refer to the following Service Information for recommended gasket sealing surface preparation procedures. If the engine diagnosis points to a faulty head gasket (leaks oil, leaks coolant, oil or coolant contamination, or air in coolant), thorough cleaning procedures are necessary for a successful head gasket repair. Diagnosis and post-repair confirmation can be done successfully utilizing leak detection methods such as a black light dye process. SERVICE PROCEDURE To sum up, a successful leak repair depends on: ^ Accurate diagnosis of the leak using Ford-recommended test equipment and procedures ^ Surface preparation and gasket installation using the approved tools, cleaners, and methods ^ Exercising CARE and CLEANLINESS during disassembly/assembly of components ^ Use of genuine Ford OEM replacement parts ^ Use of a Ford Remanufacturer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 402000, 403000, 499000 Aluminum Cylinder Head - Removal From Engine Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 2662 WARNING ALUMINUM CYLINDER HEADS ARE HIGHLY POLISHED AND MUST BE HANDLED WITH EXTREME CARE. AFTER REMOVING THE HEAD BOLTS, WITHDRAW THE HEAD FROM THE ENGINE COMPARTMENT. USE EXTREME CARE NOTING THAT THE GASKET SURFACE OF THE HEAD COULD BE DAMAGED ON THE WAY OUT OF THE VEHICLE IF ALLOWED TO HIT AGAINST OTHER ENGINE COMPONENTS. ONCE REMOVED, PLACE THE HEAD ON A BENCH, GASKET SIDE UP, USING A PIECE OF CLEAN CARDBOARD ON THE BENCH SURFACE UNDERNEATH. DO NOT SLIDE THE HEAD GASKET SURFACE ALONG THE BENCHTOP OR DAMAGE WILL OCCUR. NOTE SOME ENGINES REQUIRE A "DE-TORQUING" PROCEDURE OF THE CYLINDER HEAD BOLTS. CONSULT WITH THE APPROPRIATE MODEL YEAR WORKSHOP MANUAL FIRST, AS THIS PROCEDURE IS USUALLY DONE ON FOUR-VALVE ENGINES. HOWEVER, ALL ALUMINUM HEADS ARE PRONE TO WARPAGE DURING REMOVAL IF TAKEN OFF WHEN HOT OR WARM. THE ENGINE SHOULD BE COOLED SUFFICIENTLY BY THE TIME THE HEADS ARE ACCESSIBLE DURING TEARDOWN. ALLOW AN ADEQUATE COOL DOWN PERIOD. NOTE IN SOME ENGINE APPLICATIONS, IT MAY BE NECESSARY TO "RUBBER BAND" A FEW OF THE HEAD BOLTS TOGETHER DUE TO TIGHT CLEARANCES OF THE HEAD NEAR HEATER/AC PLENUMS AND THE BODY COWL. THIS WILL ALLOW THE BOLTS TO CLEAR THE BLOCK DECK AS THE HEAD IS WITHDRAWN FROM THE VEHICLE. Place CLEAN shop towels over the cylinder block bores to prevent further contamination from reaching internal parts and surfaces. If a towel is to be removed, do it SLOWLY . Debris collected on the towel can fall on the engine if care is not exercised as it is removed. Gasket surfaces are machined to near-mirror surface quality. Scratches, dents, gouges, and other impressions may allow oil, coolant, and compression gases to leak into other sealed cavities and/or the atmosphere. Surface imperfections deteriorate the head gasket's ability to seal effectively. Contamination on these surfaces will cause leaks from "shimming" the head even under full head bolt torque. Contamination will also cause marks on the polished gasket surface, creating a leak path. Inspection For Damage and Cleaning Procedure The overall straightness of the cylinder head and block face is held within very tight specification. Defects known as "waviness" or "depressions" cannot be surface machined out with ordinary equipment. Machining must meet manufacturer's specification on surface finish quality and be less than 0.001" inch (0.025 mm) level as measured under a known quality straightedge using a feeler gauge. If the engine has been overheated the cylinder head may have been damaged or warped. Re-surfacing will not correct this damage. The head must not contain any impressions on its sealing surface deeper than 0.001" (0.025 mm). There must not be any scratches or gouges present, especially those which track to another sealing cavity or to the atmosphere. Ensure that the mating cylinder block surface is completely free of solid contamination, corrosion, and fluids. Use Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA or equivalent, to rid the surface of any material, which could later interfere with the gasket's sealing ability. WARNING UNDER NO CIRCUMSTANCES ARE ANY ALUMINUM GASKET SURFACES TO BE CLEANED USING RAZOR BLADES, ROTARY ABRASIVE DEVICES INCLUDING ROLOC AND 3M BRANDED SCOTCHBRITE PRODUCTS, ROTARY WIRE BRUSHES, SINGLE HANDLED WIRE BRUSHES, HAND ABRASIVE SUCH AS SANDPAPER OR EMERY CLOTH, OR ANY CARBON STEEL BLADE. THESE TOOLS ARE PROVEN TO CUT AND DAMAGE ALUMINUM AND WILL DISRUPT THE POLISHED FINISH. ABRASIVE PARTICLES ARE ALSO SUSCEPTIBLE TO ENTERING THE ENGINE CAVITIES AND MAY CAUSE INTERNAL ENGINE DAMAGE. THE ONLY TOOLS ACCEPTABLE ARE PLASTIC AND WOOD SCRAPERS COMBINED WITH USE OF MOTORCRAFT METAL SURFACE CLEANER, F4AZ-19A536-RA, OR EQUIVALENT SOLVENT. The original head bolts are to be discarded. Only new head bolts are acceptable for use in a head gasket repair. Use of old bolts can cause clamp load failure because they were stretched from the last torquing procedure either from the plant or a previous field repair. The new head bolt shanks and threads should be thoroughly cleaned, dried, and lightly lubricated. Oil the bolts and let oil drip for a minimum of 5 minutes. Use of too much oil may cause hydraulic lockup in the bolt hole. The corresponding bolt holes in the cylinder block must be free of contamination consisting of dirt particles, coolant, and oil. Bolts can mechanically or hydraulically lock on top of these materials and cause for poor clamping of the cylinder head gasket. Use very lightly compressed air to blow out the bolt holes. Use care to prevent debris from scattering over the internal engine surfaces. To clean the cylinder block gasket surface, a plastic or wood scraper in combination with Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA, or equivalent solvent can be used with a portable shop vacuum. Move the scraper toward the vacuum nozzle to direct loosened material quickly away from the block surface. It is not necessary to expect aluminum head surfaces to be shiny and bright after the vehicle has been in service. Sanding, scraping, or polishing will create surface depressions that cause leaks. The surface is expected to be flat within 0.001" (0.025 mm) and free of dirt, metal chips, and liquid contaminants. Any staining of the metal surface is considered normal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 2663 Machining of aluminum heads and blocks is an unacceptable field practice for quality control purposes of flatness and surface finish standards. Removing material will also raise the risk of internal reciprocating components striking each other, as well as changing the emissions calibration of the engine. Machining practices of aluminum blocks and heads are not reimbursable. Ford Remanufacturers are authorized to perform this procedure and have the necessary equipment to put the specified surface finish on the head within original factory limits. Installation Onto the Cylinder Block Surface WARNING ANY GASKET SEALING AIDS WHICH ARE NOT LIMITED TO, AND INCLUDE AVIATION CEMENT, COPPER SPRAYS, OR GLUES ARE NOT TO BE USED. THE GASKET MUST BE FITTED DRY WITHOUT SUPPLEMENTAL SEALING AIDS. ATTEMPTS TO SEAL WITH THESE COMPOUNDS WILL CAUSE HEAD SHIMMING AND/OR NEW LEAK PATHS. THESE COMPOUNDS HAVE ALSO BEEN KNOWN TO CAUSE EMISSIONS SENSORS TO FAIL THEREBY TRIPPING FAULT CODES IN THE PCM. Ensure that all surfaces of the cylinder block, cylinder head, and gasket are fully free of any solid or liquid contamination and have been prepared for assembly using Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA, or equivalent solvent. Also ensure that any residual dirt on the engine was removed successfully from the surrounding areas of the block to head face of the head and the block. Using Workshop Manual procedures, assemble the head to the block carefully. Do not allow the gasket surfaces to scrape or bang against other engine parts. The head may pick up material along the way, if this is allowed. Once in place, with dowels properly aligned to the head and ensuring that the head is fully square, seated, and resting on the block deck in a level condition, install new "torque-to-yield" cylinder head bolts to a finger tight condition. Refer to the appropriate model year Workshop Manual for the procedure to torque the head bolts in the correct sequence and at the intervals specified. Failure to follow these instructions may result in a warped head, and damaged head bolt threads. Do not use "cheater pipes" on torque wrenches. Use a known quality, calibrated torque wrench. Pull evenly and steady on each bolt. Do not exert side pressures on the bolt hex, which can disrupt the integrity of the bolt head and give a false reading on the final torque value of the fastener. Once the engine is fully reassembled, be sure that fluid levels have been topped off as required for the operation. When the engine is ready for starting, ensure that the engine 6i1 pump is (was) primed properly and is in a "ready to start" condition with all engine oil galleys having been charged with oil. WARNING DO NOT RACE THE ENGINE UPON INITIAL STARTUP. MAINTAIN ENGINE IDLE TO BUILD OIL PRESSURE. USE OF A MECHANICAL PRESSURE GAUGE WILL ENSURE THAT OIL FLOW HAS DEVELOPED ON THE PUMP'S PRESSURE SIDE. A DEFECTIVE GAUGE OR LIGHT IN THE INSTRUMENT PANEL WILL NOT VERIFY PRESSURE HAS BEEN OBTAINED. SEVERE INTERNAL ENGINE DAMAGE WILL RESULT IF PRESSURE IS NOT OBSERVED AND STEADILY MAINTAINED. Allow a warm up period, which brings the engine to normal operating temperature. Check for leaks around the gasket joints of the head, front cover, and associated component parts. The vehicle should be road tested within normal guidelines to raise the engine to operating temperature and verify the repair is sound. Shut down the engine, allow for a cool-down and drain-back period to enable fluids to return to levels. Check fluid levels using owner guide recommendations (dipstick, sight gages, etc.). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Page 2664 Cylinder Head Gasket: Specifications Cylinder head gasket surface flatness mm (inch) ...................................................................................................................................... 0.08 (0.003) Total Head gasket surface flatness mm (inch) ................................................................................................................................................... 0.1 (0.004) overall Head gasket surface finish (RMS) ............................................................................... ............................................................................................... 60-150 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair Front Crankshaft Seal: Service and Repair Crankshaft Front Oil Seal Special Tool(s) Removal 1. Remove the crankshaft pulley. 2. Using the special tool, remove the crankshaft front oil seal. Installation 1. NOTE: Lubricate the seal lip with clean engine oil. Using the special tools and install the crankshaft front oil seal. 2. Install the crankshaft pulley. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Specifications Valve Guide Seal: Specifications Valve stem diameter intake mm (inch) .......................................................................................................................................... 6.965-6.98 (0.274-0.275) Valve stem diameter exhaust mm (inch) .................................................................................................................................................. 6.95-6.965 (0.274) Valve stem-to-guide clearance exhaust mm (inch) ....................................................................................................................... 0.035-0.068 (0.001-0.003) Valve stem-to-guide clearance intake mm (inch) ......................................................................................................................... 0.020-0.053 (0.001-0.002) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Specifications > Page 2671 Valve Guide Seal: Service and Repair Valve-Valve Seals Special Tool(s) Removal 1. Remove the valve springs. 2. Remove the valve stem seals. Installation 1. NOTE: Lubricate parts with clean engine oil prior to installing. Using the special tool, install the valve stem seals. 2. Install the valve springs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams Connector View C103 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft > Component Information > Specifications Balance Shaft: Specifications Balance shaft bolts .............................................................................................................................. ........................................... 26-28 Nm (19-21 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft Belt Tensioner > Component Information > Specifications Balance Shaft Belt Tensioner: Specifications Balance shaft tensioner bolts .......................................................................................................................................................... 28-30 Nm (21-22 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft Chain Guide > Component Information > Specifications Balance Shaft Chain Guide: Specifications Balance shaft chain guide ............................................................................................................................................................ 9-11 Nm (80-97 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Camshaft Sprocket Bolt ....................................................................................................................... .................................................... 85 Nm (63 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > Timing Drive Components - Hydraulic Chain Tensioner, RH Timing Chain Tensioner: Service and Repair Timing Drive Components - Hydraulic Chain Tensioner, RH NOTE: Ford does not provide timing marks or additional information for servicing of the timing chains/sprockets without the special tools listed in this procedure. Timing Drive Components - RH Hydraulic Chain Tensioner Removal and Installation 1. Remove the wheel and tire. 2. Remove the lower splash shield. 3. Remove the RH camshaft tensioner. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > Timing Drive Components - Hydraulic Chain Tensioner, RH > Page 2693 Timing Chain Tensioner: Service and Repair Timing Drive Components - Hydraulic Chain Tensioner, LH NOTE: Ford does not provide timing marks or additional information for servicing of the timing chains/sprockets without the special tools listed in this procedure. Timing Drive Components - LH Hydraulic Chain Tensioner Removal and Installation 1. Remove the upper intake manifold. 2. Remove the thermostat housing. 3. Remove the LH camshaft tensioner. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Engine front cover bolts ....................................................................................................................... ..................................................... 19 Nm (14 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2697 Timing Cover: Service and Repair NOTE: Ford does not provide timing marks or additional information for servicing of the timing chains/sprockets without the special tools listed in this procedure. Engine Front Cover Removal 1. Remove the radiator. 2. Remove the crankshaft pulley. 3. Remove the bolt and the wiring harness routing clip. 4. Remove the accessory bracket bolts and position the bracket aside. 5. Remove the drivebelt tensioner. 6. Disconnect the generator wiring and position the wiring aside. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2698 7. Remove the generator mounting bracket. 8. Disconnect the crankshaft position (CKP) sensor electrical connector. 9. Remove the wiring anchors and position the wiring aside. 10. Remove the wiring harness retainer and position the wiring aside. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2699 11. Remove the thermostat housing. 1 Remove the bolts. 2 Release the bypass hose clamp. 12. Release the hose clamp and remove the lower heater water hose. 13. Release the hose clamp and remove the lower radiator hose. 14. On A/C equipped vehicles, remove the A/C line bracket bolt and position the A/C line aside. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2700 15. NOTE: The water pump is removed for clarity. Remove the engine front cover. Installation 1. Clean and inspect the sealing surfaces. 2. Apply silicone gasket and sealant to the oil pan and the engine block mating surfaces. 3. Apply silicone gasket and sealant to the front cover in two places. 4. Install the engine front cover. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2701 5. On A/C equipped vehicles, install the A/C line bracket and bolt. 6. Install the lower radiator hose and clamp. 7. Install the lower heater water hose and clamp. 8. Install the thermostat housing. 1 Install the housing into the bypass hose. 2 Install the bolts. 3 Position the bypass hose clamp. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2702 9. Position the wiring harness and install the bolt. 10. Secure the wiring anchors. 11. Connect the CKP sensor electrical connector. 12. Install the generator mounting bracket. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2703 13. Connect the generator wiring. 14. Install the drivebelt tensioner. 15. Install the accessory bracket bolts. 16. Install the routing clip and bolt. 17. Install crankshaft pulley. 18. Install the radiator. 19. Raise and support the vehicle. 20. Drain the engine oil. 21. Lower the vehicle. 22. Fill the engine oil with clean engine oil. 23. Fill the engine will coolant. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System Variable Valve Timing Actuator: Description and Operation Variable Cam Timing System Overview The Variable Cam Timing System allows the exhaust cam to advance and retard at varying engine speeds. The purpose of this is to reduce exhaust emissions and increase fuel economy. As the exhaust cam retards in relation to the crankshaft position, residual exhaust gases are left in the combustion chamber. The residual gases cool the combustion chamber and are inert when mixed with the incoming fresh charge of fuel and air. This results in better fuel economy and lower Nitrogen Oxides (NOx) and Hydrocarbons (HC) the engine produces. The Exhaust Gas Recalculation System (EGR) is unnecessary on the 2.0L (4V) engine due to this feature. Variable Cam Timing Variable Cam Timing System The Variable Cam Timing (VCT) System consists of the control solenoid, five-tooth pulse ring (4+1) on exhaust camshaft, Intake Air Temperature (IAT) sensor, Engine Coolant Temperature (ECT) sensor, Camshaft Position (CMP) sensor, Mass Air Flow (MAF) sensor, Crankshaft Position (CKP) sensor, Powertrain Control Module (PCM) (Figure 127). 1. The powertrain control module (PCM) receives input signals from the intake air temperature (IAT) sensor, engine coolant temperature (ECT) sensor, camshaft position (CMP) sensor, mass air flow (MAF) sensor and crankshaft position (CKP) sensor for determining the operating conditions of the engine. 2. The Variable Cam Timing (VCT) system is enabled by the PCM when the proper conditions are met. The PCM disables the VCT system if a fault is detected. 3. The PCM calculates relative cam position using the CMP sensor and data from the (4+1) pulse ring mounted on the exhaust camshaft. Relative cam position is calculated by measuring the time between the rising edge of Profile Ignition Pickup (PIP) and the falling edge of VCT pulse. 4. The PCM continually calculates a cam position error value based on the difference between the desired and actual position and a duty cycle is commanded for the VCT solenoid valve. Engine oil is allowed to flow to the VCT unit. 5. Oil flows to either side of the piston chamber changing a linear motion from the piston to a rotation motion from the helical mechanism in the VCT unit. During closed loop the PCM outputs a revised duty cycle to the VCT solenoid valve to correct for cam position error. Hardware Variable Cam Timing (VCT) Solenoid Valve Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System > Page 2709 Variable Cam Timing (VCT) Solenoid Valve The VCT solenoid valve (Figure 128) is an integral part of the VCT system. The solenoid valve controls the flow of engine oil to the variable cam timing unit assembly. As the PCM duty cycles the solenoid valve, oil is allowed to flow to the VCT unit assembly and advance or retard the cam timing. Variable Cam Timing (VCT) Unit Assembly Variable Cam Timing Unit Assembly The variable cam timing unit assembly (Figure 129) is coupled to the camshaft through a helical spline in the VCT unit chamber. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the piston to move linearly along the axis of the camshaft. This linear motion is translated into rotational camshaft motion through the helical spline coupling. A spring installed in the chamber is designed to hold the camshaft in the minimum overlap position (5 degrees) when oil pressure is too low to maintain adequate position control. The camshaft is allowed to rotate up to 30 degrees. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System > Page 2710 Variable Valve Timing Actuator: Description and Operation Variable Cam Timing (VCT) Unit Assembly Variable Cam Timing (VCT) Unit Assembly Variable Cam Timing Unit Assembly The variable cam timing unit assembly (Figure 129) is coupled to the camshaft through a helical spline in the VCT unit chamber. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the piston to move linearly along the axis of the camshaft. This linear motion is translated into rotational camshaft motion through the helical spline coupling. A spring installed in the chamber is designed to hold the camshaft in the minimum overlap position (5 degrees) when oil pressure is too low to maintain adequate position control. The camshaft is allowed to rotate up to 30 degrees. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Description and Operation Variable Valve Timing Solenoid: Description and Operation Variable Cam Timing (VCT) Solenoid Valve Variable Cam Timing (VCT) Solenoid Valve The VCT solenoid valve (Figure 128) is an integral part of the VCT system. The solenoid valve controls the flow of engine oil to the variable cam timing unit assembly. As the PCM duty cycles the solenoid valve, oil is allowed to flow to the VCT unit assembly and advance or retard the cam timing. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Technician Safety Information Fuel Pressure Test Port: Technician Safety Information WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Technician Safety Information > Page 2720 Fuel Pressure Test Port: Vehicle Damage Warnings CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 2721 Fuel Pressure Test Port: Description and Operation Pressure Test Point There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. ON VEHICLES NOT EQUIPPED WITH A SCHRADER VALVE, USE ROTUNDA FUEL PRESSURE TEST KIT #134-R0087 OR EQUIVALENT. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 2722 Fuel Pressure Test Port: Service and Repair REMOVAL WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Remove the fuel injection supply manifold. 2. Remove the two bolts, the pressure relief valve and the O-ring seals. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. NOTE: Lubricate the new O-ring seals with clean engine oil to aid installation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > With Automatic Transmission Idle Speed: Specifications With Automatic Transmission With Flex Fuel Hot Idle ................................................................................................................................................ ......................................................... 800 - 900 RPM With Gasoline Hot Idle ................................................................................................................................................ ......................................................... 760 - 780 RPM Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > With Automatic Transmission > Page 2727 Idle Speed: Specifications With Manual Transmission Hot Idle ................................................................................................................................................ ......................................................... 760 - 880 RPM Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Service and Repair Air Cleaner Housing: Service and Repair REMOVAL 1. Disconnect the air cleaner assembly. ^ Loosen the clamp and disconnect the outlet tube. ^ Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Remove the lower air cleaner assembly. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 2735 Fuel Pressure Release: Service and Repair Fuel Pressure Gauge SPECIAL TOOL(S) WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Disconnect the battery ground cable. 2. Remove the Schrader valve cap and attach the Fuel Pressure Gauge. 3. Open the manual valve on the Fuel Pressure Gauge slowly to relieve the fuel system pressure. This may drain fuel from the system. Drain the fuel into a suitable container. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 2736 Fuel Pressure Gauge Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Coil Terminal-To-Cylinder Relationship Firing order........................................................................................................................................... ..................................................................1-4-2-5-3-6 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 2740 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 05-10-3 > May > 05 > Interior - Accelerator Pedal Vibration at 1500-1800 RPM Ignition Cable: Customer Interest Interior - Accelerator Pedal Vibration at 1500-1800 RPM TSB 05-10-3 05/30/05 ACCELERATOR PEDAL VIBRATION/BUZZ AT 1500-1800 RPM FORD: 2001-2005 Explorer Sport Trac ISSUE Some 2001-2005 Explorer Sport Trac vehicles may exhibit the accelerator pedal vibrating or buzzing at 1500-1800 RPM. ACTION Ensure the accelerator cable and the hood release cables are not contacting the # 6 spark plug wire. Reposition cables as needed. Also, ensure that the accelerator cable is secure in the retention clip, and that the clip's spring tensioner is on top. Refer to Figure 1 (incorrect position) and Figure 2 (correct position). WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9A758 43 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 05-10-3 > May > 05 > Interior - Accelerator Pedal Vibration at 1500-1800 RPM > Page 2753 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 05-10-3 > May > 05 > Interior - Accelerator Pedal Vibration at 1500-1800 RPM Ignition Cable: All Technical Service Bulletins Interior - Accelerator Pedal Vibration at 1500-1800 RPM TSB 05-10-3 05/30/05 ACCELERATOR PEDAL VIBRATION/BUZZ AT 1500-1800 RPM FORD: 2001-2005 Explorer Sport Trac ISSUE Some 2001-2005 Explorer Sport Trac vehicles may exhibit the accelerator pedal vibrating or buzzing at 1500-1800 RPM. ACTION Ensure the accelerator cable and the hood release cables are not contacting the # 6 spark plug wire. Reposition cables as needed. Also, ensure that the accelerator cable is secure in the retention clip, and that the clip's spring tensioner is on top. Refer to Figure 1 (incorrect position) and Figure 2 (correct position). WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9A758 43 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 05-10-3 > May > 05 > Interior - Accelerator Pedal Vibration at 1500-1800 RPM > Page 2759 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 2760 Ignition Cable: Service Precautions CAUTION: ^ Spark plug wires must be connected correctly. Mark the spark plug wires before removing them. ^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. ^ Be sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifold. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 2761 Ignition Cable: Service and Repair Spark Plug Wire Remover SPECIAL TOOL(S) REMOVAL 1. Remove the right front tire. 2. Remove the right front fenderwell splash shield. 3. With a twisting motion, use the special tool to pull the spark plug wires from the right side of the engine. CAUTION: ^ Spark plug wires must be connected correctly. Mark the spark plug wires before removing them. ^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. 4. Lower the vehicle. 5. With a twisting motion, use the special tool to pull the spark plug wires from the left side of the engine. CAUTION: ^ Spark plug wires must be connected correctly. Mark the spark plug wires before removing them. ^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 2762 6. Squeeze the locking tabs and twist while pulling upward to remove the spark plug wires from the ignition coil. 7. Disconnect the spark plug wires from the separators and remove the spark plug wires. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Be sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifold. NOTE: Apply silicone dielectric compound to the inside of the spark plug and ignition coil boots of the spark plug wire. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 2763 Spark Plug Wire Remover Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Spark Plug: Specifications Gap Item....................................................................................................................................................... ..............................................................Specification Spark plug gap..................................................................................................................................... ....................................1.57-1.73 mm (0.061-0.068 in) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap > Page 2768 Spark Plug: Specifications Torque Item....................................................................................................................................................... ..............................................................Specification Spark plug............................................................................................................................................ .........................................................17 Nm (13 Lb-Ft) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2769 Spark Plug: Application and ID Item....................................................................................................................................................... ..............................................................Specification Spark plug type..................................................................................................................................... ..................................................................AGSF34FP Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2770 Spark Plug: Service and Repair REMOVAL 1. Remove the spark plug wires from the spark plugs. 2. Remove the spark plugs. NOTE: ^ Use compressed air to remove any foreign material in the spark plug well before removing the spark plugs. ^ If an original spark plug is reused, make sure it is installed in the same cylinder it was taken from. New spark plugs can be used in any cylinder. 3. Inspect the spark plugs. 4. Use a suitable spark plug gap tool to check and adjust the spark plug gap. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Pressure Limit Chart The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2774 Compression Check: Testing and Inspection Compression Test-Compression Gauge Check 1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level and that the battery is correctly charged. Operate the vehicle until the engine is at normal operating temperature. Turn the ignition switch to the OFF position, then remove all the spark plugs. 2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the Compression Tester in the No. 1 cylinder. 4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position, and using the auxiliary starter switch, crank the engine a minimum of five compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Compression Test-Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Compression Test-Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. 2. If compression does not improve, valves are sticking or seating incorrectly. 3. If two adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2775 Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is within 75 percent of the highest reading. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications Water Pump: Specifications Water pump bolts ................................................................................................................................ ................................................. 10 Nm (89 inch lbs.) Water pump pulley bolts ................................... ........................................................................................................................................ 25 Nm (18 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 2779 Water Pump: Service and Repair Water Pump Removal and Installation 1. Drain the engine cooling system. 2. Remove the accessory drive belt. 3. Remove the belt idler pulley. 4. Slide the water bypass hose clamp back. 5. Disconnect the heater hose at the water pump. 1 Release the clamp. 2 Remove the hose. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 2780 6. Disconnect the lower radiator hose at the water pump. 1 Release the clamp. 2 Remove the hose. 7. Remove the water pump pulley. 8. Remove the water pump. 9. NOTE: Use metal surface cleaner and a suitable plastic or wooden scraper to clean the sealing surfaces. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Actuators and Solenoids - Cooling System > Hydraulic Cooling Fan Solenoid Valve > Component Information > Description and Operation > PCM Outputs Hydraulic Cooling Fan Solenoid Valve: Description and Operation PCM Outputs Visctronic Drive Fan (VDF) Visctronic Drive Fan (VDF) Visctronic Drive Fan (VDF) Clutch The primary purpose for the Visctronic Drive Fan (VDF) clutch is to optimize fan energy (i.e. improved fuel economy) while meeting cooling performance requirements. Successful optimization will also minimize objectionable fan noise. The operation is similar to the existing viscous fan clutch, except viscous fluid flow is controlled by a Pulse Width Modulated (PWM) solenoid versus a bi-metal temperature sensor on the front of the clutch. The VDF consists of three main elements, a working chamber, a reservoir chamber, and a Fan Speed Sensor (FANSS). A fluid port valve controls fluid flow from the reservoir into the working chamber. Once viscous fluid is in the working chamber, "shearing" of the fan clutch fluid will result in fan rotation. The valve is activated via a pulse width modulated (PWM) output signal from the PCM. By opening and closing the fluid port valve, the PCM can control approximate fan speed. Fan speed is monitored via a Hall-Effect sensor and is read by the PCM for closed loop operation. The PCM will optimize the VDF fan speed based upon CHT, TFT, or AT cooling requirements. When either of these inputs is demanding increased fan speed for vehicle cooling, the PCM will monitor the Hall Effect Fan Speed Sensor (FANSS), and output the resultant PWM signal to the fluid port valve thus controlling to the required fan speed. Fan Control Fan Control TAURUS/SABLE: PCM FC Output State For Cooling Fan Speeds Chart ESCAPE: PCM FC Output State For Cooling Fan Speeds Chart The PCM monitors certain parameters (such as engine coolant temperature, vehicle speed, A/C on/off status, A/C pressure, etc) to determine engine Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Actuators and Solenoids - Cooling System > Hydraulic Cooling Fan Solenoid Valve > Component Information > Description and Operation > PCM Outputs > Page 2787 cooling fan needs. The PCM controls the fan operation through the Fan Control (FC) (single speed fan applications), Low Fan Control (LFC), Medium Fan Control (MFC) and/or High Fan Control (HFC) outputs. Although the PCM output circuits for three speed tans are called low, medium and high fan control (FC), cooling fan speed is controlled by a combination of these outputs. Refer to the table. Hydraulic Cooling Fan Drive Hydraulic Cooling Fan Drive Hydraulic Cooling Fan Pump With Integral Solenoid The system consists of an engine-driven pump with an integral solenoid (Figure 49) on the pump that is triggered by the powertrain control module (PCM). Fan speed is controlled by adjusting current to the solenoid, which then changes the fluid flow to the hydraulic motor. More current means the solenoid opens up, allowing higher pressure to increase the fan speed. The fan always turns due to solenoid current leakage, even in cold engine cases. The motor is driven by the pump. It contains a shaft on which the fan mounts. The motor also contains quick connect fittings for the high pressure lines. The cooler is similar to the power steering cooler (same purpose and function, to keep the fluid cool). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - Premium Gold Coolant Service Info Coolant: Technical Service Bulletins Cooling System - Premium Gold Coolant Service Info Article No. 02-23-7 11/25/02 COOLING SYSTEM - MOTORCRAFT PREMIUM GOLD ENGINE COOLANT - SERVICE TIPS FORD: 2002-2003 ESCORT ZX2, FOCUS, MUSTANG, TAURUS, THUNDERBIRD 2003 CROWN VICTORIA 2002 EXCURSION 2002-2003 E SERIES, ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT, EXPLORER, F-150, RANGER, SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS. 2003 EXPEDITION, WINDSTAR 2002-2003 F-650, F-750 LINCOLN: 2002 CONTINENTAL 2002-2003 LS 2003 TOWN CAR 2002-2003 BLACKWOOD 2003 AVIATOR, NAVIGATOR MERCURY: 2002-2003 SABLE 2003 GRAND MARQUIS 2002-2003 MOUNTAINEER Article 02-17-7 is being republished in its entirety to update the text and part numbers. ISSUE A new, extended-life engine coolant, yellow-colored Motorcraft Premium Gold Engine Coolant, meeting Ford Specification WSS-M97B51-A1, service part numbers VC-7-A and VC-7-C (for use in the U.S., except California and Oregon) and VC-7-B (for use only in California and Oregon as it contains a bittering agent), has been equipped in all of the vehicles noted above. The initial-fill life for this coolant is 100,000 miles/5 years. Due to variations in water quality, the replacement interval is 50,000 miles/3 years. ACTION Any time the addition of coolant or a coolant change-out is required, USE ONLY THE TYPE OF ENGINE COOLANT WITH WHICH THE VEHICLE WAS ORIGINALLY EQUIPPED. DO NOT MIX COOLANT TYPES. To determine the type of coolant required, check the color of coolant in the coolant reservoir of the vehicle or refer to the applicable vehicle's Owner's Guide or Workshop Manual for service parts and specification information. SERVICE INFORMATION Except for heavy-duty vehicles equipped with the Caterpillar 3126E engine, the use of a supplemental coolant additive (SCA) such as Motorcraft Heavy-Duty Cooling System Additive, service part number FW-16, is not required in conjunction with this coolant. Testing is currently underway to determine the backward compatibility of the Motorcraft Premium Gold Engine Coolant in vehicles equipped with the green-colored Motorcraft Premium Engine Coolant, service part numbers VC-4-A, VC-4-B, and VC-5. Until the final test results are available, vehicles should ONLY be serviced with type of coolant with which they were originally equipped. Please note that Motorcraft Premium Gold Engine Coolant is not compatible with any orange-colored, extended-life engine coolants such as Motorcraft Specialty Orange Engine Coolant, service part numbers VC-2 and VC-3. DO NOT MIX COOLANT TYPES. USE ONLY THE TYPE OF COOLANT WITH WHICH THE VEHICLE WAS EQUIPPED. Failure to follow these guidelines may result in degradation of corrosion protection and potential engine damage. Coolant Discoloration: The current Motorcraft Cooling System Stop Leak Pellets, service part number VC-6, used in both Production and Service, cause the yellow-colored Motorcraft Premium Gold Engine Coolant to change color ranging from a light golden brown to dark brown, depending upon the amount of pellet Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - Premium Gold Coolant Service Info > Page 2792 material in the coolant reservoir. This discoloration does not adversely affect the coolant or the vehicle's cooling system components. No repairs are required for this condition. To avoid confusion with regard to coolant contamination, a new formulation of stop leak pellets will be implemented in Production and Service in the near future. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 02-17-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - Premium Gold Coolant Service Info > Page 2793 Coolant: Technical Service Bulletins Engine Coolant - Propylene Glycol Recommendations Article No. 01-23-6 11/26/01 ^ ENGINE COOLANT - PROPYLENE GLYCOL - FORD MOTOR COMPANY POSITION ON ENGINE COOLANTS MADE FROM PROPYLENE GLYCOL ^ ENGINE COOLANT - PROPYLENE GLYCOL-BASED - FORD MOTOR COMPANY POSITION ON PROPYLENE GLYCOL-BASED ENGINE COOLANTS FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2002 FOCUS 2002 THUNDERBIRD 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT 2000-2002 F-650, F-750 LINCOLN: 1989-1992 MARK VII 1989-2002 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1989-1994 TOPAZ 1989-1997 COUGAR 1989-2002 GRAND MARQUIS, SABLE 1991-1994 CAPRI 1991-1999 TRACER 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER MERKUR: 1989 SCORPIO, XR4TI This article is being republished in its entirety to update the model year coverage. ISSUE This TSB article describes Ford Motor Company's position on the use of propylene glycol-based engine coolants. ACTION Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - Premium Gold Coolant Service Info > Page 2794 Ford Motor Company does not recommend nor endorse the use of engine coolants made with propylene glycol in Ford vehicles. Ford Motor Company currently recommends the use of ethylene glycol-based engine coolants. Published information suggests that engine coolants made with propylene glycol may provide engine cooling performance equivalent to engine coolants made with ethylene glycol. However, different brands of engine coolant provide varying corrosion protection for the cooling system. Ford does not have performance data for the multitude of engine coolants available in the aftermarket and therefore cannot recommend the use of any coolant except those sold by Ford Customer Service Division. Consult the vehicle's Owner's Guide to determine the appropriate Ford Customer Service Division coolant for the vehicle. Furthermore, claims of toxicological and environmental advantages of propylene glycol over ethylene glycol may be misleading. When significant new information is developed, Ford will review this policy. Ford Motor Company specifications recommend that vehicles be maintained using certain ethylene glycol-based engine coolants. Those specifications do not refer to engine coolants made with propylene glycol. Although the Ford New Vehicle Limited Warranty is not automatically voided upon the use of a coolant made with propylene glycol, if such use results in damage to the vehicle or its components, the cost of repairing the damage would not be covered by the Ford New Vehicle Limited Warranty. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-16-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Cooling System Capacity System Capacity ........................................................................................ ........................................................................................ 13.2 liters (14.0 quarts) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 2797 Coolant: Fluid Type Specifications Motorcraft Premium Engine Coolant ........................................................................................................................... VC-4-A (in Oregon VC-5, in Canada CXC-10) or equivalent (green color) Motorcraft Premium Gold Engine Coolant ..................................................................................................................................................... VC-7-A (in Oregon VC-7-B) or equivalent (yellow color) NOTE: Use the same type of coolant that was drained from the cooling system. Do not mix coolant types. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Specifications Coolant Reservoir: Specifications Coolant expansion tank ....................................................................................................................... ................................................. 10 Nm (89 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Specifications > Page 2801 Coolant Reservoir: Service and Repair Coolant Expansion Tank Removal and Installation 1. Remove the air cleaner outlet tube and the engine air cleaner. 2. Remove the bolt and position the speed control servo aside. 3. Disconnect the windshield washer hose from under the dash panel and plug the end of the hose. 4. Disconnect the windshield washer pump electrical connector from the windshield washer reservoir. 5. Disconnect and plug the overflow hose. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Specifications > Page 2802 6. Remove the two nuts and bolts, and the coolant expansion tank. 7. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Specifications Fan Blade: Specifications Fan blade-to-fan clutch bolts ............................................................................................................... ................................................. 10 Nm (89 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Specifications Fan Clutch: Specifications Fan clutch bolts ................................................................................................................................... ...................................................... 22 Nm (16 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Description and Operation > PCM Output Fan Clutch: Description and Operation PCM Output Fan Control Fan Control TAURUS/SABLE: PCM FC Output State For Cooling Fan Speeds Chart ESCAPE: PCM FC Output State For Cooling Fan Speeds Chart The PCM monitors certain parameters (such as engine coolant temperature, vehicle speed, A/C on/off status, A/C pressure, etc) to determine engine cooling fan needs. The PCM controls the fan operation through the Fan Control (FC) (single speed fan applications), Low Fan Control (LFC), Medium Fan Control (MFC) and/or High Fan Control (HFC) outputs. Although the PCM output circuits for three speed tans are called low, medium and high fan control (FC), cooling fan speed is controlled by a combination of these outputs. Refer to the table. Hydraulic Cooling Fan Drive Hydraulic Cooling Fan Drive Hydraulic Cooling Fan Pump With Integral Solenoid The system consists of an engine-driven pump with an integral solenoid (Figure 49) on the pump that is triggered by the powertrain control module (PCM). Fan speed is controlled by adjusting current to the solenoid, which then changes the fluid flow to the hydraulic motor. More current means the solenoid opens up, allowing higher pressure to increase the fan speed. The fan always turns due to solenoid current leakage, even in cold engine cases. The motor is driven by the pump. It contains a shaft on which the fan mounts. The motor also contains quick connect fittings for the high pressure Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Description and Operation > PCM Output > Page 2812 lines. The cooler is similar to the power steering cooler (same purpose and function, to keep the fluid cool). Visctronic Drive Fan (VDF) Visctronic Drive Fan (VDF) Visctronic Drive Fan (VDF) Clutch The primary purpose for the Visctronic Drive Fan (VDF) clutch is to optimize fan energy (i.e. improved fuel economy) while meeting cooling performance requirements. Successful optimization will also minimize objectionable fan noise. The operation is similar to the existing viscous fan clutch, except viscous fluid flow is controlled by a Pulse Width Modulated (PWM) solenoid versus a bi-metal temperature sensor on the front of the clutch. The VDF consists of three main elements, a working chamber, a reservoir chamber, and a Fan Speed Sensor (FANSS). A fluid port valve controls fluid flow from the reservoir into the working chamber. Once viscous fluid is in the working chamber, "shearing" of the fan clutch fluid will result in fan rotation. The valve is activated via a pulse width modulated (PWM) output signal from the PCM. By opening and closing the fluid port valve, the PCM can control approximate fan speed. Fan speed is monitored via a Hall-Effect sensor and is read by the PCM for closed loop operation. The PCM will optimize the VDF fan speed based upon CHT, TFT, or AT cooling requirements. When either of these inputs is demanding increased fan speed for vehicle cooling, the PCM will monitor the Hall Effect Fan Speed Sensor (FANSS), and output the resultant PWM signal to the fluid port valve thus controlling to the required fan speed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Description and Operation > Page 2813 Fan Clutch: Tools and Equipment Fan Clutch Holding Tool AST tool# 8005 Allows the technician to hold the water pump pulleuy in place while loosening the radiator fan. 2009 Suggested user price: $41.20 Assenmacher Specialty Tools 1 800 525 2943 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Hydraulic Cooling Fan Solenoid Valve > Component Information > Description and Operation > PCM Outputs Hydraulic Cooling Fan Solenoid Valve: Description and Operation PCM Outputs Visctronic Drive Fan (VDF) Visctronic Drive Fan (VDF) Visctronic Drive Fan (VDF) Clutch The primary purpose for the Visctronic Drive Fan (VDF) clutch is to optimize fan energy (i.e. improved fuel economy) while meeting cooling performance requirements. Successful optimization will also minimize objectionable fan noise. The operation is similar to the existing viscous fan clutch, except viscous fluid flow is controlled by a Pulse Width Modulated (PWM) solenoid versus a bi-metal temperature sensor on the front of the clutch. The VDF consists of three main elements, a working chamber, a reservoir chamber, and a Fan Speed Sensor (FANSS). A fluid port valve controls fluid flow from the reservoir into the working chamber. Once viscous fluid is in the working chamber, "shearing" of the fan clutch fluid will result in fan rotation. The valve is activated via a pulse width modulated (PWM) output signal from the PCM. By opening and closing the fluid port valve, the PCM can control approximate fan speed. Fan speed is monitored via a Hall-Effect sensor and is read by the PCM for closed loop operation. The PCM will optimize the VDF fan speed based upon CHT, TFT, or AT cooling requirements. When either of these inputs is demanding increased fan speed for vehicle cooling, the PCM will monitor the Hall Effect Fan Speed Sensor (FANSS), and output the resultant PWM signal to the fluid port valve thus controlling to the required fan speed. Fan Control Fan Control TAURUS/SABLE: PCM FC Output State For Cooling Fan Speeds Chart ESCAPE: PCM FC Output State For Cooling Fan Speeds Chart The PCM monitors certain parameters (such as engine coolant temperature, vehicle speed, A/C on/off status, A/C pressure, etc) to determine engine Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Hydraulic Cooling Fan Solenoid Valve > Component Information > Description and Operation > PCM Outputs > Page 2818 cooling fan needs. The PCM controls the fan operation through the Fan Control (FC) (single speed fan applications), Low Fan Control (LFC), Medium Fan Control (MFC) and/or High Fan Control (HFC) outputs. Although the PCM output circuits for three speed tans are called low, medium and high fan control (FC), cooling fan speed is controlled by a combination of these outputs. Refer to the table. Hydraulic Cooling Fan Drive Hydraulic Cooling Fan Drive Hydraulic Cooling Fan Pump With Integral Solenoid The system consists of an engine-driven pump with an integral solenoid (Figure 49) on the pump that is triggered by the powertrain control module (PCM). Fan speed is controlled by adjusting current to the solenoid, which then changes the fluid flow to the hydraulic motor. More current means the solenoid opens up, allowing higher pressure to increase the fan speed. The fan always turns due to solenoid current leakage, even in cold engine cases. The motor is driven by the pump. It contains a shaft on which the fan mounts. The motor also contains quick connect fittings for the high pressure lines. The cooler is similar to the power steering cooler (same purpose and function, to keep the fluid cool). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations View 151-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Engine Coolant Temperature (ECT) Sender Connector View C1061 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Engine Coolant Temperature (ECT) Sender > Page 2825 Connector View C1064 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2826 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Engine Coolant Temperature (ECT) Sensor The Engine Coolant Temperature (ECT) sensor (Figure 27) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. The ECT sensor is similar in construction to the IAT sensor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2827 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector. 2. Remove the retaining clip and the ECT sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Description and Operation Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor Cylinder Head Temperature (CHT) Sensor The Cylinder Head Temperature (CHT) sensor (Figure 26) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The cylinder head temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. For additional information, refer to Powertrain Control Software for Fail-Safe Cooling Strategy details. See: Powertrain Management/Description and Operation/Powertrain Control Software Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications Temperature Sensor (Gauge): Specifications Engine coolant temperature (ECT) sensor ............................................................................................................................................ 10 Nm (89 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications > Page 2834 Temperature Sensor (Gauge): Service and Repair Sender Unit-Water Temperature Indicator Removal and Installation 1. Partially drain the cooling system. 2. Remove the thermostat. 3. Disconnect the electrical connector. 4. Remove the water temperature indicator sending unit. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Specifications Fan Shroud: Specifications Fan shroud bolts .................................................................................................................................. ................................................. 10 Nm (89 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Specifications > Page 2838 Fan Shroud: Service and Repair Cooling Fan Shroud Special Tool(s) Removal and Installation 1. Remove the air cleaner outlet tube. 2. Using the special tools remove the fan blade and clutch assembly. 3. Remove the bolts, and the fan blade and shroud. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Control Valve > Component Information > Service and Repair Heater Control Valve: Service and Repair REMOVAL 1. Prepare the vehicle for heater water control valve assembly removal. 1 Drain the engine coolant. 2 Remove the air cleaner assembly. 2. Disconnect the vacuum hose and heater hose. 3. Remove the retaining pins. Position the inner fender well access mat out of the way. 4. Disconnect the heater hose. Remove the bolt and the heater water control valve assembly. INSTALLATION 1. To install, reverse the removal procedure. - Lubricate the coolant hoses with MERPOL(R) meeting Ford specification ESE-M99B144-B or plain water only, if needed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2850 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2851 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2857 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2858 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 2859 Heater Core: Service Precautions WARNING: - CARBON MONOXIDE IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS NECESSARY TO OPERATE THE ENGINE WITH THE VEHICLE IN A CLOSED AREA SUCH AS A GARAGE, ALWAYS USE AN EXHAUST COLLECTOR TO VENT THE EXHAUST GASES OUTSIDE THE CLOSED AREA. THE HEATER CORE INLET HOSE WILL BECOME TOO HOT TO HANDLE IF THE SYSTEM IS WORKING CORRECTLY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 2860 Heater Core: Description and Operation The heater core consists of fins and tubes arranged to extract heat from the engine coolant and transfer it to air passing through the heater core. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 2861 Heater Core: Testing and Inspection WARNING: CARBON MONOXIDE IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS NECESSARY TO OPERATE THE ENGINE WITH THE VEHICLE IN A CLOSED AREA SUCH AS A GARAGE, ALWAYS USE AN EXHAUST COLLECTOR TO VENT THE EXHAUST GASES OUTSIDE THE CLOSED AREA. 1. Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A coolant leak in the heater water hose could follow the heater core tube to the heater core and appear as a leak in the heater core. NOTE: Testing of returned heater cores reveals that a large percentage of heater cores are good and did not require installation of a new heater core. If a heater core leak is suspected, the heater core must be tested by following the plugged heater core component test before the heater core pressure test. Carry out a system inspection by checking the heater system thoroughly. 2. Check the integrity of the heater water hose clamps. NOTE: Spring-type clamps are installed as original equipment. Installation and overtightening of non-specification clamps can cause leakage at the heater water hose connection and damage the heater core. Heater Core - Plugged WARNING: THE HEATER CORE INLET HOSE WILL BECOME TOO HOT TO HANDLE IF THE SYSTEM IS WORKING CORRECTLY. 1. Check to see that the engine coolant is at the correct level. 2. Start the engine and turn on the heater. 3. When the engine coolant reaches operating temperature, feel the heater core outlet hose to see if it is hot. If it is not hot: the heater control valve is not working correctly. - the heater core may have an air pocket. - the heater core may be plugged. - the thermostat is not working correctly. Heater Core - Pressure Test Use Pressure Tester to carry out the pressure test. 1. Drain the coolant from the cooling system. NOTE: Due to space limitations, a bench test may be necessary for pressure testing. 2. Disconnect the heater water hoses from the heater core. 3. Install a short piece of heater water hose, approximately 101 mm (4 inches) long on each heater core tube. 4. Fill the heater core and heater water hoses with water and install Plug BT-7422-B and adapter BT-7422-A from the radiator/heater core pressure tester in the heater water hose ends. Secure the heater water hoses, plug and adapter with hose clamps. 5. Attach the pump and gauge assembly from the Pressure Tester to the adapter. 6. Close the bleed valve at the base of the gauge. Pump 241 kPa (35 psi) of air pressure into the heater core. 7. Observe the pressure gauge for a minimum of three minutes. 8. If the pressure drops, check the heater water hose connections to the core tubes for leaks. If the heater water hoses do not leak, remove the heater core from the vehicle and carry out the bench test. Heater Core - Bench Test 1. Remove the heater core from the vehicle. 2. Drain all of the coolant from the heater core. 3. Connect the 101 mm (4 inch) test heater water hoses with plug and adapter to the core tubes. Then connect the radiator/heater core pressure tester to the adapter. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 2862 4. Apply 241 kPa (35 psi) of air pressure to the heater core. Submerge the heater core in water. 5. If a leak is observed, install a new heater core. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 2863 Heater Core: Service and Repair REMOVAL 1. Prepare the vehicle for heater core removal. 1 Remove the A/C evaporator housing. 2 Remove the instrument panel. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Removal and Installation, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 3 Remove the Powertrain Control Module (PCM). NOTE: If a heater core leak is suspected, the heater core must be leak tested before it is removed from the vehicle. 2. Remove the PCM heat sink. 1 Remove the ground strap screw. 2 Remove the heat sink. 3. Remove the four nuts from the engine side of the dash panel. Position the plenum chamber on the vehicle floor. 4. Remove the heater core cover. 1 Remove the screws. 2 Remove the heater core cover. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 2864 5. Remove the heater core. - During installation, be sure to install a new oval foam seal around the heater core inlet and outlet tubes. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2873 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2874 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2880 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2881 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Specifications Radiator: Specifications Radiator-to-radiator support bolts ........................................................................................................................................................ 10 Nm (89 inch lbs.) Transmission cooling line fitting to radiator ............................................................................................................................................. 25 Nm (18 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Specifications > Page 2885 Radiator: Service and Repair Radiator Removal and Installation 1. Drain the cooling system. 2. Remove the air cleaner outlet tube. 3. Disconnect and remove the overflow hose. 4. Remove the cooling fan shroud. 5. Disconnect the upper radiator hose from the radiator. 6. Disconnect the lower radiator hose from the radiator. 7. NOTE: To avoid disturbing the transmission oil cooler fittings, use a backup wrench. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Specifications > Page 2886 Disconnect the two transmission cooling lines. 8. Remove the two bolts and the radiator. 9. Position aside EVAP test port. 10. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Specifications Radiator Cap: Specifications Cap ...................................................................................................................................................... ............................................ 189-124 kPa (13-18 psi) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations View 151-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Engine Coolant Temperature (ECT) Sender Connector View C1061 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Engine Coolant Temperature (ECT) Sender > Page 2897 Connector View C1064 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2898 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Engine Coolant Temperature (ECT) Sensor The Engine Coolant Temperature (ECT) sensor (Figure 27) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. The ECT sensor is similar in construction to the IAT sensor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2899 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector. 2. Remove the retaining clip and the ECT sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Description and Operation Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor Cylinder Head Temperature (CHT) Sensor The Cylinder Head Temperature (CHT) sensor (Figure 26) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The cylinder head temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. For additional information, refer to Powertrain Control Software for Fail-Safe Cooling Strategy details. See: Powertrain Management/Description and Operation/Powertrain Control Software Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications Temperature Sensor (Gauge): Specifications Engine coolant temperature (ECT) sensor ............................................................................................................................................ 10 Nm (89 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications > Page 2906 Temperature Sensor (Gauge): Service and Repair Sender Unit-Water Temperature Indicator Removal and Installation 1. Partially drain the cooling system. 2. Remove the thermostat. 3. Disconnect the electrical connector. 4. Remove the water temperature indicator sending unit. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications Thermostat Opening Temperature Starts to open ............................................................................................................................................................ 90-94 degrees C (183- 190 degrees F) Fully open ............................................................................. ................................................................................................ 105 degrees C (210 degrees F) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2910 Thermostat: Description and Operation Thermostat Heater Control Thermostat Assembly With Heater Control The primary objective for the thermostat heater control is for improvement in the economy and thermal efficiency. The system consists of a high temperature (98°C/208°F in lieu of a 90°C/194°F) thermostat (Figure 50) that has a resistive heater within the wax element. The heater is controlled by the PCM dependent on engine speed, throttle position, engine load, vehicle speed, air charge temperature, transmission oil temperature and engine coolant temperature. During low speed, low load and low air charge temperature conditions, the thermostat heater is OFF and the engine is allowed to operate at an elevated coolant temperature. This should result in lower internal friction and higher thermal efficiency, both leading to improved fuel economy. During high speed, high load, high temperature conditions (air charge, transmission oil or engine coolant), the PCM output is energized with a duty cycle to the thermostat heater. This heats the wax and forces the thermostat to rapidly open wider allowing extra coolant to flow from the radiator. This will reduce the coolant temperature and improve with performance demand. It should be noted that the heater is only capable of supplying a SMALL amount of additional heat to the wax element; it is NOT capable of opening the thermostat alone. The thermostat is 100% duty cycle for short calibrated time and than the duty cycle is reduce to a maximum of 70% on and 30% off. Approximately, unheated, the thermostat will begin to open at a coolant temperature of 98°C (208°F) and will be fully open at 115°C (239°F). Energizing the heater will reduce the opening temperature to about 80°C (176°F) and the fully open temperature to 110°C (230°F). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2911 Thermostat: Service and Repair Thermostat Removal and Installation 1. Drain the engine cooling system. 2. Remove the air cleaner outlet tube. 3. Remove the upper radiator hose extension. 4. Remove the bolts water outlet adapter and thermostat. ^ Inspect the O-ring seal, install a new O-ring seal if necessary. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Specifications Thermostat Housing: Specifications Thermostat housing bolts .................................................................................................................... ........................................................ 11 Nm (8 ft. lbs.) Thermostat housing bolts ................................ ..................................................................................................................................... 10 Nm (89 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications Water Pump: Specifications Water pump bolts ................................................................................................................................ ................................................. 10 Nm (89 inch lbs.) Water pump pulley bolts ................................... ........................................................................................................................................ 25 Nm (18 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2918 Water Pump: Service and Repair Water Pump Removal and Installation 1. Drain the engine cooling system. 2. Remove the accessory drive belt. 3. Remove the belt idler pulley. 4. Slide the water bypass hose clamp back. 5. Disconnect the heater hose at the water pump. 1 Release the clamp. 2 Remove the hose. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2919 6. Disconnect the lower radiator hose at the water pump. 1 Release the clamp. 2 Remove the hose. 7. Remove the water pump pulley. 8. Remove the water pump. 9. NOTE: Use metal surface cleaner and a suitable plastic or wooden scraper to clean the sealing surfaces. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Customer Interest: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur Smell Technical Service Bulletin # 02-21-6 Date: 021028 Engine Controls/Emissions - Exhaust Sulfur Smell Article No. 02-21-6 10/28/02 ^ DRIVEABILITY - EXCESSIVE SULFUR SMELL FROM EXHAUST ^ EXHAUST - EXCESSIVE SULFUR SMELL FROM EXHAUST FORD: 2001-2002 EXPLORER SPORT 2002 EXPLORER SPORT TRAC 2002-2003 EXPLORER MERCURY: 2002-2003 MOUNTAINEER Article 02-16-6 is being republished in its entirety to update the Service Procedure and model years. ISSUE Some vehicles may exhibit excessive sulfur smell from the exhaust under certain drive modes. This may be due to the highly active state of a new catalyst, calibration factors, underbody catalyst temperature, and amount of sulfur present in the fuel. ACTION Identify year, model, and build date to identify appropriate service procedure. For applications that require installing exhaust wrap, use good quality stainless steel worm-drive hose clamps for best longevity, similar to what would commonly be used for exhaust heat shield rattle issues. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 02-16-6 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 022106A Install Exhaust Wrap And 1.4 Hrs. Perform Drive Sequence. 2002-2003 Explorer/Mountaineer 4.0L Vehicles Built 1-14-02 Through 12-02-02, 4.6L Built Prior To 12-02-02 022106B Install Exhaust Wrap, 1.6 Hrs. Reprogram Powertrain Control Module And Perform Drive Sequence. 2002-2003 Explorer/Mountaineer 4.0L Built Prior To 1-14-02 022106C Replace Catalytic 0.8 Hr. Converter And Reprogram Powertrain Control Module. 2001-2002 Explorer Sport Vehicles Built 7-24-00 Through 3-4-02, 2002 Sport Trac 11-02-01 Through 3-4-02 022106D Replace Catalytic 0.6 Hr. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Customer Interest: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur Smell > Page 2929 Converter Only. 2002 Explorer Sport/Sport Trac 3-4-02 Through 3-27-02 With Automatic Transmission, 11-02-01 Through 3-4-02 With Manual Transmission DEALER CODING CONDITION BASIC PART NO. CODE 5F250 42 OASIS CODES: 403000, 499000 Disclaimer Service Procedure 2002-2003 4 DOOR EXPLORER/MOUNTAINEER 4.0L Vehicles Built 1/14/02 Through 12/02/2002 At latest level for engine calibration. 1. Install Exhaust wrap on the pipes between the light-off and the underbody catalyst referring to the instruction sheet in the kit. 2. Refer to Drive Sequence heading to purge stored sulfur from catalyst. 3. See Contributing Factors heading for additional information. NOTE CONVERTER REPLACEMENT OR RECALIBRATION IS NOT NECESSARY. Vehicles Built Before 1/14/02 1. Verify that WDS is at the latest level, B21.0 or higher. 2. Reprogram the PCM with the latest calibration. 3. Install Exhaust wrap on the pipes between the light-off and the underbody catalyst referring to the instruction sheet in the kit. 4. Refer to Drive Sequence heading to purge stored sulfur from catalyst. 5. See Contributing Factors Heading for additional information. NOTE DO NOT REPLACE THE CONVERTER. 2002-2003 4 DOOR EXPLORER/MOUNTAINEER 4.6L Vehicles Built Prior To 12/02/2002 1. Install Exhaust wrap on the pipes between the light-off and the underbody catalyst referring to the instruction sheet in the kit. 2. Refer to Drive Sequence heading to purge stored sulfur from catalyst. 3. See Contributing Factors Heading for additional information. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Customer Interest: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur Smell > Page 2930 NOTE CONVERTER REPLACEMENT OR RECALIBRATION IS NOT NECESSARY. 2001-2002 2 DOOR EXPLORER SPORT 4.0L 7/24/00 Through 3/4/02 With 5R55E Transmission 1. Refer to 2001/2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the old catalytic converter and install the revised converter 2L2Z-5E212-DA. 2. Verify that WDS is at the latest level, B21.0 or higher. 3. Reprogram the PCM with the latest calibration only. 4. See Contributing Factors Heading for additional information. NOTE DO NOT REPLACE CONVERTER MORE THAN ONCE. 2002 2 DOOR EXPLORER SPORT/SPORT TRAC 4.0L Vehicles Built After 3/27/02 At latest level for engine calibration and converter, no service action will improve the situation. 1. See Contributing Factors Heading for additional information. 3/4/02 Through 3/27/02 1. Refer to 2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the old catalytic converter and install the revised converter 2L2Z-5E212-AB only. 2. See Contributing Factors Heading for additional information. NOTE DO NOT REPLACE CONVERTER MORE THAN ONCE OR RECALIBRATE. 2002 2 DOOR EXPLORER SPORT/SPORT TRAC 4.0L M5R4 MANUAL TRANSMISSION 11/2/01 Through 3/4/02 With Manual Transmission 1. Refer to 2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the old catalytic converter and install the revised converter 2L2Z-5E212-DA only. 2. See Contributing Factors Heading for additional information. NOTE DO NOT REPLACE CONVERTER MORE THAN ONCE OR RECALIBRATE. 2002 SPORT TRAC 4.0L 5R55E TRANSMISSION 11/2/01 Through 3/4/02 With 5R55E Transmission 1. Refer to 2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the old catalytic converter and install the revised converter 2L2Z-5E212-DA. 2. Verify that WDS is at the latest level, B21.0 or higher. 3. Reprogram the PCM with the latest calibration. 4. See Contributing Factors Heading for additional information. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Customer Interest: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur Smell > Page 2931 NOTE DO NOT REPLACE CONVERTER MORE THAN ONCE. DRIVE SEQUENCE AFTER REPAIRS COMPLETED Check engine oil and coolant levels. Verify both are at specified levels before driving vehicle. Perform highway driving at normal highway speeds for 30 miles. The optimum engine speed for this drive sequence is 3,000 to 4,500 rpm, and this can be accomplished by manually selecting the transmission gear state. The goal of the drive procedure is to maintain a constant high temperature level in the exhaust system through the use of increased engine speed. The combination of increased temperature and driving will provide a sulfur cleaning environment for the catalyst system. CONTRIBUTING FACTORS TO SULFUR SMELL Factors outside of engineering control may lead to a sulfur odor. A large contributing factor is the amount of sulfur in the fuel. Replacing a Catalytic Converter multiple times will not alleviate the sulfur odor. Several catalyst replacements on the same vehicle may actually increase customer sensitivity to an exhaust odor concern. Based on some driving habits the converter does not get hot enough to burn out stored sulfur residue and can produce a sulfur odor. For example: ^ Extended Idle - Increase sulfur odor ^ Stop and go driving - Increase sulfur odor ^ Trailer Towing - Decrease sulfur odor ^ Heavy Loads - Decrease sulfur odor Short trips - Increase sulfur odor ^ Abrupt accel/decel - Decrease sulfur odor ^ Hotter driving conditions - Decrease sulfur odor ^ Hilly terrain - Decrease sulfur odor ^ Canceling Overdrive - Decrease sulfur odor Catalysts with 5,000-10,000 Miles (8,000-16,000 kilometers) are likely to have a sulfur smell due to the highly active state of the new catalyst. Refer to symptom chart # 22 of PCED for appropriate year. Additives in fuels (Ethanol, Methanol, ETC.) can cause sulfur odor, suggest using a different fuel source. Geographic variations on sulfur odor intensity are possible due to different refineries supplying fuel to different areas of the country. California regulated fuel will exhibit less sulfur odor. Experiment with different fuel brands. Some contain more sulfur than others, which can lead to an increase in sulfur odor from the converter. Sulfur odors are an aromatic phenomenon and do not cause any durability or safety concerns with vehicle operation. To summarize for the customer, explain that sulfur is in the fuel used and the catalyst system on their vehicle as a result of the fuel and driving environment which creates a condition where sulfur has been stored in their exhaust system. The service action performed allows the sulfur to pass through the exhaust system and to clean the existing sulfur deposits. During the initial cleansing of the catalyst it is expected that a sulfur odor may still be present, and this odor may change from the "rotten egg smell" to that of a "burning match". The odor will cease with time. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Customer Interest: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur Smell > Page 2932 PCM Calibration Information Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Customer Interest: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur Smell > Page 2933 SUPERSEDES:02-16-6 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 022106A Install Exhaust Wrap And 1.4 Hrs. Perform Drive Sequence. 2002-2003 Explorer/Mountaineer 4.0L Vehicles Built 1-14-02 Through 12-02-02, 4.6L Built Prior To 12-02-02 022106B Install Exhaust Wrap, 1.6 Hrs. Reprogram Powertrain Control Module And Perform Drive Sequence. 2002-2003 Explorer/Mountaineer 4.0L Built Prior To 1-14-02 022106C Replace Catalytic 0.8 Hr. Converter And Reprogram Powertrain Control Module. 2001-2002 Explorer Sport Vehicles Built 7-24-00 Through 3-4-02, 2002 Sport Trac 11-02-01 Through 3-4-02 022106D Replace Catalytic 0.6 Hr. Converter Only. 2002 Explorer Sport/Sport Trac 3-4-02 Through 3-27-02 With Automatic Transmission, 11-02-01 Through 3-4-02 With Manual Transmission DEALER CODING CONDITION BASIC PART NO. CODE 5F250 42 OASIS CODES: 403000, 499000 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Component Information > Description and Operation Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor Intake Air Temperature (IAT) The Intake Air Temperature (IAT) sensors (Figure 33) and integrated Mass Air Flow (MAF) type (Figure 36), are thermistor devices in which resistance changes with temperature The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of fuel, spark and MAF. The IAT sensor provides a quicker temperature change response time than the ECT or CHT sensor. Supercharged vehicles use (2) IAT sensors. Both sensors are thermistor type devices and operate as above. However, one is located before the supercharger at the air cleaner for standard OBD II/cold weather input, while a second sensor (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control border-line spark and to help determine intercooler efficiency. Currently two types of IAT2 sensors are used. A screw in type (Figure 33) and an integrated type, witch is part of the Thermal Manifold Absolute Pressure (TMAP) sensor (Figure 40). The TMAP sensor consists of a IAT thermistor and a Manifold Absolute Pressure (MAP) sensor. The thermistor portion of the TMAP is used for IAT2 function and operates in the same manner as a non-integrated IAT2. For additional information on the MAP portion of the TMAP, refer to the Thermal Manifold Absolute Pressure Sensor description and operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 01-11-10 > Jun > 01 > Customer Interest for Catalytic Converter: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur Smell Technical Service Bulletin # 02-21-6 Date: 021028 Engine Controls/Emissions - Exhaust Sulfur Smell Article No. 02-21-6 10/28/02 ^ DRIVEABILITY - EXCESSIVE SULFUR SMELL FROM EXHAUST ^ EXHAUST - EXCESSIVE SULFUR SMELL FROM EXHAUST FORD: 2001-2002 EXPLORER SPORT 2002 EXPLORER SPORT TRAC 2002-2003 EXPLORER MERCURY: 2002-2003 MOUNTAINEER Article 02-16-6 is being republished in its entirety to update the Service Procedure and model years. ISSUE Some vehicles may exhibit excessive sulfur smell from the exhaust under certain drive modes. This may be due to the highly active state of a new catalyst, calibration factors, underbody catalyst temperature, and amount of sulfur present in the fuel. ACTION Identify year, model, and build date to identify appropriate service procedure. For applications that require installing exhaust wrap, use good quality stainless steel worm-drive hose clamps for best longevity, similar to what would commonly be used for exhaust heat shield rattle issues. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 02-16-6 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 022106A Install Exhaust Wrap And 1.4 Hrs. Perform Drive Sequence. 2002-2003 Explorer/Mountaineer 4.0L Vehicles Built 1-14-02 Through 12-02-02, 4.6L Built Prior To 12-02-02 022106B Install Exhaust Wrap, 1.6 Hrs. Reprogram Powertrain Control Module And Perform Drive Sequence. 2002-2003 Explorer/Mountaineer 4.0L Built Prior To 1-14-02 022106C Replace Catalytic 0.8 Hr. Converter And Reprogram Powertrain Control Module. 2001-2002 Explorer Sport Vehicles Built 7-24-00 Through 3-4-02, 2002 Sport Trac 11-02-01 Through 3-4-02 022106D Replace Catalytic 0.6 Hr. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 01-11-10 > Jun > 01 > Customer Interest for Catalytic Converter: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur Smell > Page 2945 Converter Only. 2002 Explorer Sport/Sport Trac 3-4-02 Through 3-27-02 With Automatic Transmission, 11-02-01 Through 3-4-02 With Manual Transmission DEALER CODING CONDITION BASIC PART NO. CODE 5F250 42 OASIS CODES: 403000, 499000 Disclaimer Service Procedure 2002-2003 4 DOOR EXPLORER/MOUNTAINEER 4.0L Vehicles Built 1/14/02 Through 12/02/2002 At latest level for engine calibration. 1. Install Exhaust wrap on the pipes between the light-off and the underbody catalyst referring to the instruction sheet in the kit. 2. Refer to Drive Sequence heading to purge stored sulfur from catalyst. 3. See Contributing Factors heading for additional information. NOTE CONVERTER REPLACEMENT OR RECALIBRATION IS NOT NECESSARY. Vehicles Built Before 1/14/02 1. Verify that WDS is at the latest level, B21.0 or higher. 2. Reprogram the PCM with the latest calibration. 3. Install Exhaust wrap on the pipes between the light-off and the underbody catalyst referring to the instruction sheet in the kit. 4. Refer to Drive Sequence heading to purge stored sulfur from catalyst. 5. See Contributing Factors Heading for additional information. NOTE DO NOT REPLACE THE CONVERTER. 2002-2003 4 DOOR EXPLORER/MOUNTAINEER 4.6L Vehicles Built Prior To 12/02/2002 1. Install Exhaust wrap on the pipes between the light-off and the underbody catalyst referring to the instruction sheet in the kit. 2. Refer to Drive Sequence heading to purge stored sulfur from catalyst. 3. See Contributing Factors Heading for additional information. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 01-11-10 > Jun > 01 > Customer Interest for Catalytic Converter: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur Smell > Page 2946 NOTE CONVERTER REPLACEMENT OR RECALIBRATION IS NOT NECESSARY. 2001-2002 2 DOOR EXPLORER SPORT 4.0L 7/24/00 Through 3/4/02 With 5R55E Transmission 1. Refer to 2001/2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the old catalytic converter and install the revised converter 2L2Z-5E212-DA. 2. Verify that WDS is at the latest level, B21.0 or higher. 3. Reprogram the PCM with the latest calibration only. 4. See Contributing Factors Heading for additional information. NOTE DO NOT REPLACE CONVERTER MORE THAN ONCE. 2002 2 DOOR EXPLORER SPORT/SPORT TRAC 4.0L Vehicles Built After 3/27/02 At latest level for engine calibration and converter, no service action will improve the situation. 1. See Contributing Factors Heading for additional information. 3/4/02 Through 3/27/02 1. Refer to 2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the old catalytic converter and install the revised converter 2L2Z-5E212-AB only. 2. See Contributing Factors Heading for additional information. NOTE DO NOT REPLACE CONVERTER MORE THAN ONCE OR RECALIBRATE. 2002 2 DOOR EXPLORER SPORT/SPORT TRAC 4.0L M5R4 MANUAL TRANSMISSION 11/2/01 Through 3/4/02 With Manual Transmission 1. Refer to 2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the old catalytic converter and install the revised converter 2L2Z-5E212-DA only. 2. See Contributing Factors Heading for additional information. NOTE DO NOT REPLACE CONVERTER MORE THAN ONCE OR RECALIBRATE. 2002 SPORT TRAC 4.0L 5R55E TRANSMISSION 11/2/01 Through 3/4/02 With 5R55E Transmission 1. Refer to 2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the old catalytic converter and install the revised converter 2L2Z-5E212-DA. 2. Verify that WDS is at the latest level, B21.0 or higher. 3. Reprogram the PCM with the latest calibration. 4. See Contributing Factors Heading for additional information. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 01-11-10 > Jun > 01 > Customer Interest for Catalytic Converter: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur Smell > Page 2947 NOTE DO NOT REPLACE CONVERTER MORE THAN ONCE. DRIVE SEQUENCE AFTER REPAIRS COMPLETED Check engine oil and coolant levels. Verify both are at specified levels before driving vehicle. Perform highway driving at normal highway speeds for 30 miles. The optimum engine speed for this drive sequence is 3,000 to 4,500 rpm, and this can be accomplished by manually selecting the transmission gear state. The goal of the drive procedure is to maintain a constant high temperature level in the exhaust system through the use of increased engine speed. The combination of increased temperature and driving will provide a sulfur cleaning environment for the catalyst system. CONTRIBUTING FACTORS TO SULFUR SMELL Factors outside of engineering control may lead to a sulfur odor. A large contributing factor is the amount of sulfur in the fuel. Replacing a Catalytic Converter multiple times will not alleviate the sulfur odor. Several catalyst replacements on the same vehicle may actually increase customer sensitivity to an exhaust odor concern. Based on some driving habits the converter does not get hot enough to burn out stored sulfur residue and can produce a sulfur odor. For example: ^ Extended Idle - Increase sulfur odor ^ Stop and go driving - Increase sulfur odor ^ Trailer Towing - Decrease sulfur odor ^ Heavy Loads - Decrease sulfur odor Short trips - Increase sulfur odor ^ Abrupt accel/decel - Decrease sulfur odor ^ Hotter driving conditions - Decrease sulfur odor ^ Hilly terrain - Decrease sulfur odor ^ Canceling Overdrive - Decrease sulfur odor Catalysts with 5,000-10,000 Miles (8,000-16,000 kilometers) are likely to have a sulfur smell due to the highly active state of the new catalyst. Refer to symptom chart # 22 of PCED for appropriate year. Additives in fuels (Ethanol, Methanol, ETC.) can cause sulfur odor, suggest using a different fuel source. Geographic variations on sulfur odor intensity are possible due to different refineries supplying fuel to different areas of the country. California regulated fuel will exhibit less sulfur odor. Experiment with different fuel brands. Some contain more sulfur than others, which can lead to an increase in sulfur odor from the converter. Sulfur odors are an aromatic phenomenon and do not cause any durability or safety concerns with vehicle operation. To summarize for the customer, explain that sulfur is in the fuel used and the catalyst system on their vehicle as a result of the fuel and driving environment which creates a condition where sulfur has been stored in their exhaust system. The service action performed allows the sulfur to pass through the exhaust system and to clean the existing sulfur deposits. During the initial cleansing of the catalyst it is expected that a sulfur odor may still be present, and this odor may change from the "rotten egg smell" to that of a "burning match". The odor will cease with time. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 01-11-10 > Jun > 01 > Customer Interest for Catalytic Converter: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur Smell > Page 2948 PCM Calibration Information Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 01-11-10 > Jun > 01 > Customer Interest for Catalytic Converter: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur Smell > Page 2949 SUPERSEDES:02-16-6 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 022106A Install Exhaust Wrap And 1.4 Hrs. Perform Drive Sequence. 2002-2003 Explorer/Mountaineer 4.0L Vehicles Built 1-14-02 Through 12-02-02, 4.6L Built Prior To 12-02-02 022106B Install Exhaust Wrap, 1.6 Hrs. Reprogram Powertrain Control Module And Perform Drive Sequence. 2002-2003 Explorer/Mountaineer 4.0L Built Prior To 1-14-02 022106C Replace Catalytic 0.8 Hr. Converter And Reprogram Powertrain Control Module. 2001-2002 Explorer Sport Vehicles Built 7-24-00 Through 3-4-02, 2002 Sport Trac 11-02-01 Through 3-4-02 022106D Replace Catalytic 0.6 Hr. Converter Only. 2002 Explorer Sport/Sport Trac 3-4-02 Through 3-27-02 With Automatic Transmission, 11-02-01 Through 3-4-02 With Manual Transmission DEALER CODING CONDITION BASIC PART NO. CODE 5F250 42 OASIS CODES: 403000, 499000 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Component Information > Locations Fuel Pump Relay: Locations Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Component Information > Locations > Page 2952 Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Component Information > Locations > Page 2953 Connector View C1051 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Component Information > Locations > Page 2954 Fuel Pump Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Component Information > Locations > Page 2955 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Component Information > Diagrams Connector View C257 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Component Information > Diagrams > Page 2959 Clutch Switch: Description and Operation Clutch Pedal Position Switch Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch (Figure 24) is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Component Information > Description and Operation Absolute Pressure Sensor: Description and Operation Thermal Manifold Absolute Pressure Sensor Thermal Manifold Absolute Pressure (TMAP) Sensor The Thermal Manifold Absolute Pressure Sensor (TMAP) (Figure 40) consists of a Manifold Absolute Pressure (MAP) sensor and an integrated thermistor. The thermistor part of the sensor is currently not being used. The MAP part of the sensor measures intake manifold air absolute pressure. The PCM uses information from the MAP sensor, Throttle Position (TP) sensor, mass air flow (MAF) sensor, engine coolant temperature (ECT) or cylinder head temperature (CHT) sensor and crankshaft position (CKP) sensor to determine how much exhaust gas is introduced into the intake manifold. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Exhaust manifold nuts ......................................................................................................................... ..................................................... 22 Nm (16 ft. lbs.) Exhaust manifold to exhaust pipe bolts .................................................................................................................................................... 40 Nm (30 ft. lbs.) Converter-to-manifold nuts ......................................................................................... .............................................................................. 40 Nm (30 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 2965 Exhaust Manifold: Description and Operation Exhaust Manifold/Runners The exhaust manifold runners collect exhaust gases from engine cylinders. The number of exhaust manifolds and exhaust manifold runners depends on the engine configuration and number of cylinders. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold-LH Exhaust Manifold: Service and Repair Exhaust Manifold-LH Exhaust Manifold-LH Removal and Installation 1. Raise and support the vehicle. 2. Remove the bolts. 3. Lower the vehicle. 4. Disconnect the hoses from the differential pressure feedback (EGR) transducer. 5. Disconnect the EGR valve to exhaust manifold tube from the exhaust manifold. 6. Disconnect the EGR valve to exhaust manifold tube from the EGR valve and remove the EGR valve to exhaust manifold tube. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold-LH > Page 2968 7. Remove the LH exhaust manifold. 8. NOTE: Use new exhaust manifold gaskets and nuts. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold-LH > Page 2969 Exhaust Manifold: Service and Repair Exhaust Manifold-RH Exhaust Manifold-RH Removal 1. Raise and support the vehicle. 2. Remove the bolts. 3. Lower the vehicle. 4. Remove the RH exhaust manifold. 5. NOTE: Use new exhaust manifold gaskets and nuts. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Specifications Exhaust Pipe: Specifications Dual converter Y-pipe to dual three-way nuts .......................................................................................................................................... 40 Nm (30 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Specifications > Page 2973 Exhaust Pipe: Description and Operation Exhaust Pipes Exhaust pipes are usually treated during manufacturing with an anti-corrosive coating agent to increase the life of the product. The pipes serve as guides for the flow of exhaust gases from the engine exhaust manifold through the catalytic converter and the muffler. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Specifications > Page 2974 Exhaust Pipe: Service and Repair Dual Converter Y-Pipe Removal and Installation 1. Remove the dual three-way catalytic converter. 2. Disconnect the heated oxygen sensors. 3. Remove the LH nuts. 4. Remove the RH nuts and remove the dual converter Y-pipe. 5. Remove the converter inlet gasket and, if necessary, the heated oxygen sensors. ^ Discard the gasket. 6. CAUTION: Make sure that the dual converter Y-pipe to exhaust manifold nuts are tightened after the three-way catalytic converter is installed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Specifications > Page 2975 NOTE: Make sure to apply anti-seize lubricant to the threads of the sensors before installation. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications Heat Shield: Specifications Exhaust heat shield clamps ................................................................................................................. ..................................................... 7 Nm (62 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications > Page 2979 Heat Shield: Service and Repair Exhaust Heat Shield-Catalytic Converter and Muffler 1. Raise the vehicle. 2. Inspect the catalytic converter and muffler for loose or missing heat shields. 3. Install worm clamps for heat shields that are loose. ^ Use one of the following clamps: ^ FOTZ-SA231-A or W705949-S300. ^ Trim off the excess ear of the worm clamp. 4. If the heat shields are missing, install new heat shields. If new heat shields are not available, install a new catalytic converter. 5. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Specifications Muffler: Specifications Muffler-to-converter bolts and nuts .......................................................................................................................................................... 40 Nm (30 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Specifications > Page 2983 Muffler: Description and Operation Muffler Mufflers are usually treated during manufacturing with an anti-corrosive coating agent to increase the life of the product. The muffler reduces the level of noise produced by the engine, and it also reduces the noise produced by exhaust gases as they travel from the catalytic converter to the atmosphere. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Specifications > Page 2984 Muffler: Service and Repair Muffler And Tailpipe Removal and Installation All vehicles 1. Raise and support the vehicle. 2. Remove the bolts and springs. Sport Trac vehicles 3. Remove the bolt and position the shock absorber out of the way. All vehicles 4. Remove the nut and position the right-hand stabilizer bar link out of the way. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Specifications > Page 2985 5. Detach the tailpipe from the isolator. 6. Detach the muffler from the isolators and remove the muffler and tailpipe. 7. Remove the converter outlet pipe gasket. ^ Discard the gasket. 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 2997 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 2998 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 2999 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures Powertrain Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 3005 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 3006 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3011 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3012 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3013 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures Powertrain Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 3019 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 3020 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3021 View 151-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3022 Powertrain Control Module: Diagrams Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3023 Part 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3024 Powertrain Control Module: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the Powertrain Control Module (PCM) electrical connector. 3. Remove the nuts and the PCM cover. 4. Remove the PCM. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Powertrain Control Module Power Relay: Locations Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3028 Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3029 Connector View C1016 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3030 Powertrain Control Module Power Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3031 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Emission Control Systems > Air Injection Pump Relay > Component Information > Description and Operation Air Injection Pump Relay: Description and Operation Solid State Relay Solid State Relay The solid state relay (Figure 124) switches the high current required for operation of the electric AIR pump. Input control to the solid state relay comes from the powertrain control module (PCM). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Description and Operation Fuel Pump Control Unit: Description and Operation Fuel Pump Driver Module Applications Fuel Pump Driver Module Duty Cycle Signals The Fuel Pump Driver Module (FPDM) communicates diagnostic information to the powertrain control module (PCM) through the Fuel Pump Monitor (FPM) circuit. This information is sent by the FPDM as a duty cycle signal. The three duty cycle signals that may be sent are listed in the table. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3043 Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3044 Connector View C1051 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3045 Fuel Pump Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3046 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Powertrain Control Module Power Relay: Locations Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3050 Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3051 Connector View C1016 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3052 Powertrain Control Module Power Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3053 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Description and Operation Absolute Pressure Sensor: Description and Operation Thermal Manifold Absolute Pressure Sensor Thermal Manifold Absolute Pressure (TMAP) Sensor The Thermal Manifold Absolute Pressure Sensor (TMAP) (Figure 40) consists of a Manifold Absolute Pressure (MAP) sensor and an integrated thermistor. The thermistor part of the sensor is currently not being used. The MAP part of the sensor measures intake manifold air absolute pressure. The PCM uses information from the MAP sensor, Throttle Position (TP) sensor, mass air flow (MAF) sensor, engine coolant temperature (ECT) or cylinder head temperature (CHT) sensor and crankshaft position (CKP) sensor to determine how much exhaust gas is introduced into the intake manifold. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations View 151-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3062 Connector View C128 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3063 Mass Air Flow Sensor: Service Precautions CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3064 Mass Air Flow Sensor: Description and Operation Mass Air Flow Sensor Typical Mass Air Flow (MAF) Sensor Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire Terminals The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 35). If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio (Figure 36). This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3065 Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated intake air temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar, Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3066 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Loosen the air cleaner outlet tube clamp and position the tube aside. 3. Remove the four bolts and the MAF sensor. CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations View 151-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3070 Connector View C180 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > PCM Input Camshaft Position Sensor: Description and Operation PCM Input Camshaft Position Sensor The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No.1 is on its compression stroke. A signal is then sent to the powertrain control module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctance Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22) and the two pin connector variable reluctance sensor (Figure 23). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > PCM Input > Page 3073 Camshaft Position Sensor: Description and Operation Ignition Systems Camshaft Position Sensor Camshaft Position (CMP) Sensor The camshaft position sensor (Figure 55) used by COP Integrated EI system is a magnetic transducer mounted on the engine front cover adjacent to the camshaft. By monitoring a target on the camshaft sprocket, the CMP sensor identifies cylinder one to the PCM. The COP Integrated EI system uses this information to synchronize the firing of the individual coils. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 3074 Camshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams Connector View C257 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams > Page 3078 Clutch Switch: Description and Operation Clutch Pedal Position Switch Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch (Figure 24) is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations View 151-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Engine Coolant Temperature (ECT) Sender Connector View C1061 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Engine Coolant Temperature (ECT) Sender > Page 3084 Connector View C1064 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 3085 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Engine Coolant Temperature (ECT) Sensor The Engine Coolant Temperature (ECT) sensor (Figure 27) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. The ECT sensor is similar in construction to the IAT sensor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 3086 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector. 2. Remove the retaining clip and the ECT sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations View 151-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3090 Connector View C101 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > PCM Input Crankshaft Position Sensor: Description and Operation PCM Input Crankshaft Position Sensor (Integrated Ignition Systems) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the powertrain control module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to fixed reference (Figure 25). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > PCM Input > Page 3093 Crankshaft Position Sensor: Description and Operation Ignition Systems Crankshaft Position Sensor Typical Crankshaft Position (CKP) Sensor The crankshaft position (CKP) sensor (Figure 54) is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP sensor is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to a fixed reference (Figure 54) for the CKP sensor configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between teeth. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Page 3094 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Crankshaft Position (CKP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ The new CKP sensor needs to be touching the damper. The new sensor has wear tabs that will wear off after several engine revolutions. ^ Be sure the sensor wiring is routed away from the battery cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor Cylinder Head Temperature (CHT) Sensor The Cylinder Head Temperature (CHT) sensor (Figure 26) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The cylinder head temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. For additional information, refer to Powertrain Control Software for Fail-Safe Cooling Strategy details. See: Description and Operation/Powertrain Control Software Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions Fuel Tank Pressure Sensor: Service Precautions CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions > Page 3101 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure Sensor Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The Fuel Tank Pressure (FTP) sensor (Figure 97) or inline fuel tank pressure (FTP) sensor (Figure 98) is used to measure the fuel tank pressure during the EVAP monitor test on vehicles equipped with the Running Loss-type system. Also, it is used to control excessive fuel tank pressure by forcing the system to purge. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions > Page 3102 Fuel Tank Pressure Sensor: Service and Repair REMOVAL 1. Remove the fuel tank. 2. Remove the fuel tank pressure sensor. 1 Disconnect the electrical connector. 2 Press down and rotate the fuel tank pressure sensor counterclockwise and remove it from the fuel tank. CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. INSTALLATION 1. To install, reverse removal procedure. ^ Leak test. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Evaporative Emission System Leak Test ^ Carry out the evaporative emissions repair verification drive cycle. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Evaporative Emission Repair Verification Drive Cycle Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Description and Operation Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor Intake Air Temperature (IAT) The Intake Air Temperature (IAT) sensors (Figure 33) and integrated Mass Air Flow (MAF) type (Figure 36), are thermistor devices in which resistance changes with temperature The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of fuel, spark and MAF. The IAT sensor provides a quicker temperature change response time than the ECT or CHT sensor. Supercharged vehicles use (2) IAT sensors. Both sensors are thermistor type devices and operate as above. However, one is located before the supercharger at the air cleaner for standard OBD II/cold weather input, while a second sensor (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control border-line spark and to help determine intercooler efficiency. Currently two types of IAT2 sensors are used. A screw in type (Figure 33) and an integrated type, witch is part of the Thermal Manifold Absolute Pressure (TMAP) sensor (Figure 40). The TMAP sensor consists of a IAT thermistor and a Manifold Absolute Pressure (MAP) sensor. The thermistor portion of the TMAP is used for IAT2 function and operates in the same manner as a non-integrated IAT2. For additional information on the MAP portion of the TMAP, refer to the Thermal Manifold Absolute Pressure Sensor description and operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations View 151-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3109 Connector View C109 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3110 Knock Sensor: Description and Operation Knock Sensor Knock Sensor (KS) The knock Sensor (KS) (Figure 34) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3111 Knock Sensor: Service and Repair REMOVAL 1. Disconnect the Knock Sensor (KS) electrical connector. 2. Remove the intake manifold. 3. Remove the KS. 1 Remove the bolt. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Description and Operation Oil Temperature Sensor For ECM: Description and Operation Engine Oil Temperature Engine Oil Temperature (EOT) Sensor The Engine Oil Temperature (EOT) sensor (Figure 29) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The EOT measures the temperature of the engine oil. The EOT sensor is similar in construction to the engine coolant temperature (ECT) sensor. On some applications, EOT input to the PCM is used to initiate a soft engine shutdown. This prevents engine damage from occurring as a result of high oil temperature. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions Heated Oxygen Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. NOTE: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3120 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number or the component name in one of the the A-Z Component Lists, the Component Location description for that component can easily be found. See: Locations/Component Locations/A-Z Component List Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3121 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3122 the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3123 that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3124 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3125 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3126 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3127 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3128 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3129 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3130 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3131 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3132 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3133 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3134 Systems Overview Wire Color Code Identification Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3135 OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3136 Heated Oxygen Sensor: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3137 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3138 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3139 Heated Oxygen Sensor: Connector Views Connector View C171 Connector View C142 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3140 Connector View C172 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 3141 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > PCM Input Heated Oxygen Sensor: Description and Operation PCM Input Heated Oxygen Sensor Heated Oxygen Sensor (HO2S) The Heated Oxygen Sensor (HO2S) (Figure 32) detects the presence of oxygen in the exhaust and produces a variable voltage according to the amount of oxygen detected. A high concentration of oxygen (lean air/fuel ratio) in the exhaust produces a low voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a high voltage signal greater than 0.6 volt. The HO2S provides feedback to the PCM indicating air/fuel ratio in order to achieve a near stoichiometric air/fuel ratio of 14.7:1 during closed loop engine operation. The HO2S generates a voltage between 0.0 and 1.1 volts. Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to temperatures of 800°C (1400°F). At approximately 300°C (600°F) the engine can enter closed loop operation. The VPWR circuit supplies voltage to the heater and the PCM will complete the ground when the proper conditions occur. For model year 1998 a new HO2S heater and heater control system are installed on some vehicles. The high power heater reaches closed loop fuel control temperatures. The use of this heater requires that the HO2S heater control be duty cycled, to prevent damage to the heater. The 6 ohm design is not interchangeable with new style 3.3 ohm heater. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > PCM Input > Page 3144 Heated Oxygen Sensor: Description and Operation Upstream Heated and Downstream Heated Oxygen Sensors Upstream Heated and Downstream Heated Oxygen Sensors The HO2S provide the Powertrain Control Module (PCM) with voltage and frequency information related to the oxygen content of the exhaust gas. (Refer to the PCM Inputs for a description of how the HO2S operates.) In addition to providing the PCM with indications of how rich/lean the engine is operating, the upstream HO2S signal serves as an input to the HO2S monitor. The downstream HO2S signal is an input to the Catalyst Efficiency monitor. (Refer to the OBD II Monitors for specific information on these monitors.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Page 3145 Heated Oxygen Sensor: Service and Repair Socket, Exhaust Gas Oxygen Sensor SPECIAL TOOL(S) REMOVAL Left side sensor 1. Raise and support the vehicle. Right side sensor 2. Remove the right front wheel and tire assembly. 3. Position aside the right front fender splash shield. Both sensors 4. Using the special tool, remove the HO2S. NOTE: If necessary, lubricate the HO2S with lock lubricant to assist in removal. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Apply a light coat of anti-seize lubricant to the threads of the HO2S. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Page 3146 Socket, Exhaust Gas Oxygen Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3155 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3156 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3157 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3158 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3159 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3165 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3166 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3167 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3168 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3169 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3174 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3175 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3176 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3182 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3183 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3184 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3185 View 151-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3186 Connector View C1068 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3187 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR Sensor Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 86) is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Tube Mounted Differential Pressure Feedback EGR Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3188 Tube Mounted Differential Pressure Feedback EGR Sensor The tube mounted differential pressure feedback EGR sensor (Figure 87) is identical in operation as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the underside of the sensor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3189 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the differential pressure feedback Exhaust Gas Recirculation (EGR). 1 Disconnect the electrical connector. 2 Disconnect the hoses. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations View 151-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3193 Connector View C189 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3194 Throttle Position Sensor: Description and Operation Throttle Position Sensor Typical Throttle Position (TP) Sensor The throttle position (TP) sensor (Figure 41) is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is monitored by the OBD II system for component integrity, system functionality, and faults that can cause emissions levels to exceed standards set in government regulations. For additional information on the TP sensor, refer to Electronic EC System Hardware-PCM Inputs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3195 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove the accelerator control snow shield. 2. Remove the Throttle Position (TP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolts and the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission Range (TR) sensor screws .......................................................................................................................... 8-11 Nm (71-97 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3199 View 151-5 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3200 Connector View C167 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3201 Digital Transmission Range Sensor: Description and Operation Digital Transmission Range (TR) Sensor The digital Transmission Range (TR) sensor is located on the outside of the transmission at the manual lever. The digital TR sensor completes the start circuit in PARK, NEUTRAL, and the back-up lamp circuit in REVERSE. The digital TR sensor also opens and closes a set of four switches that are monitored by the Powertrain Control Module (PCM) to determine the position of the manual lever (P, R, N, (D), 3, 2, 1). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3202 Digital Transmission Range Sensor: Service and Repair Digital Transmission Range (TR) Sensor Special Tools Special Tool(s) Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Disconnect the shift cable from the manual control lever. 4. Disconnect the digital Transmission Range (TR) sensor electrical connector. 5. Remove the manual control outer lever nut and manual control outer lever. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3203 6. Remove the screws and the digital TR sensor. Installation 1. Install the digital TR sensor and loosely install the screws. 2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence. 3. Install the manual control outer lever and nut. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3204 4. Connect the digital Transmission Range (TR) sensor electrical connector. 5. Connect the shift cable to the manual control lever. 6. Verify that the shift cable is adjusted. 7. Lower the vehicle. 8. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > PCM Input Vehicle Speed Sensor: Description and Operation PCM Input Vehicle Speed Sensor Typical Vehicle Speed Sensor (VSS) The Vehicle Speed Sensor (VSS) (Figure 44) is a variable reluctance or Hall-effect sensor that generates a waveform with a frequency that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the VSS (and other inputs) to control such parameters as fuel injection, ignition control, transmission/transaxle shift scheduling and torque converter clutch scheduling. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > PCM Input > Page 3209 Vehicle Speed Sensor: Description and Operation PCM Output Powertrain Control Module - Vehicle Speed Output (VSO) The PCM-VSO (Powertrain Control Module - Vehicle Speed Output) speed signal subsystem generates vehicle speed information for distribution to the vehicle's electrical/electronic modules and subsystems that require vehicle speed data. This subsystem senses the transmission output shaft speed with a sensor. The data is processed by the PCM, and distributed as a hard-wired signal or as a multiplexed data message. The key features of the PCM-VSO system are to: ^ Infer vehicle movement from the output shaft sensor signal ^ Convert transmission output shaft rotational information to vehicle speed information ^ Compensate for tire size and axle ratio with a programmed calibration variable ^ Utilize a transfer case sensor for four wheel drive applications ^ Distribute vehicle speed information as a multiplexed message and/or an analog signal The signal from a non-contact shaft sensor (Output Shaft Sensor--OSS or Transfer Case Shaft Sensor--TCSS) mounted on the transmission (automatics, manuals, or 4X4 transfer cases) is sensed directly by the PCM. The PCM converts the OSS or TCSS information to 8000 pulses per mile, based on a tire and axle ratio conversion factor. This conversion factor is programmed into the PCM at the time the vehicle is assembled and can be reprogrammed in the field for servicing changes in the tire size and axle ratio. The PCM transmits the computed vehicle speed and distance traveled information to all the vehicle speed signal users on the vehicle. VSO information can be transmitted by a hard-wired interface between the vehicle speed signal user and the PCM, or by Speed and Odometer SCP multiplexed data messages. The VSO hard-wired signal wave form is a DC square wave with a voltage level of 0 to VBAT. Typical output operating range is 2.22Hz per MPH ( 1.3808 Hz pr 1 Km/h). Multiplexed data for speed and distance data are transmitted as separate SCP messages over the SCP multiplex link. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3219 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3220 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3221 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3222 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3223 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3229 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3230 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3231 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3232 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3233 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3238 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3239 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3240 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 3246 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 3247 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 3248 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3249 View 151-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3250 Connector View C1068 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3251 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR Sensor Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 86) is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Tube Mounted Differential Pressure Feedback EGR Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3252 Tube Mounted Differential Pressure Feedback EGR Sensor The tube mounted differential pressure feedback EGR sensor (Figure 87) is identical in operation as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the underside of the sensor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3253 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the differential pressure feedback Exhaust Gas Recirculation (EGR). 1 Disconnect the electrical connector. 2 Disconnect the hoses. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations View 151-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3258 Connector View C128 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3259 Mass Air Flow Sensor: Service Precautions CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3260 Mass Air Flow Sensor: Description and Operation Mass Air Flow Sensor Typical Mass Air Flow (MAF) Sensor Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire Terminals The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 35). If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio (Figure 36). This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3261 Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated intake air temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar, Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3262 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Loosen the air cleaner outlet tube clamp and position the tube aside. 3. Remove the four bolts and the MAF sensor. CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations View 151-15 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 3266 Connector View C435 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 3267 Fuel Pressure Sensor/Switch: Description and Operation Fuel Rail Pressure Sensor Fuel Rail Pressure (FRP) Sensor The Fuel Rail Pressure (FRP) sensor (Figure 30) is a diaphragm strain gauge device in which resistance changes with pressure. The electrical resistance of a strain gauge increases as pressure increases, and decreases as pressure decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to pressure. Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. Fuel Rail Pressure (FRP) Sensor The fuel rail pressure (FRP) sensor (Figure 31) senses the pressure difference between the fuel rail and the intake manifold. The return fuel line to the fuel tank has been deleted in this type of fuel system. The differential fuel/intake manifold pressure together with measured fuel temperature provides an indication of the fuel vapors in the fuel rail. Both differential pressure and temperature feedback signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserve fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and Operation Fuel Temperature Sensor: Description and Operation Engine Fuel Temperature Sensor Engine Fuel Temperature (EFT) Sensor The Engine Fuel Temperature (EFT) sensor (Figure 28) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The EFT sensor measures the temperature of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations View 151-11 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3274 Connector View C282 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3275 Inertia Fuel Shutoff Switch: Description and Operation Inertia Fuel Shutoff (IFS) Switch The Inertia Fuel Shutoff (IFS) switch (Figure 72) is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shut off the fuel pump if a collision occurs. It consists of a steel ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and shuts off the electric fuel pump. Once the switch is open, it must be manually reset before restarting the vehicle. Refer to the Owner Guide for the location of the IFS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3276 Inertia Fuel Shutoff Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Access the Inertia Fuel Shutoff (IFS) switch on the RH A-pillar lower trim panel and disconnect the electrical connector. 3. Remove the bolts and remove the IFS switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations View 151-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3280 Connector View C189 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3281 Throttle Position Sensor: Description and Operation Throttle Position Sensor Typical Throttle Position (TP) Sensor The throttle position (TP) sensor (Figure 41) is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is monitored by the OBD II system for component integrity, system functionality, and faults that can cause emissions levels to exceed standards set in government regulations. For additional information on the TP sensor, refer to Electronic EC System Hardware-PCM Inputs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3282 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove the accelerator control snow shield. 2. Remove the Throttle Position (TP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolts and the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations View 151-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3287 Connector View C180 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > PCM Input Camshaft Position Sensor: Description and Operation PCM Input Camshaft Position Sensor The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No.1 is on its compression stroke. A signal is then sent to the powertrain control module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctance Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22) and the two pin connector variable reluctance sensor (Figure 23). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > PCM Input > Page 3290 Camshaft Position Sensor: Description and Operation Ignition Systems Camshaft Position Sensor Camshaft Position (CMP) Sensor The camshaft position sensor (Figure 55) used by COP Integrated EI system is a magnetic transducer mounted on the engine front cover adjacent to the camshaft. By monitoring a target on the camshaft sprocket, the CMP sensor identifies cylinder one to the PCM. The COP Integrated EI system uses this information to synchronize the firing of the individual coils. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 3291 Camshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations View 151-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3295 Connector View C101 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > PCM Input Crankshaft Position Sensor: Description and Operation PCM Input Crankshaft Position Sensor (Integrated Ignition Systems) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the powertrain control module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to fixed reference (Figure 25). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > PCM Input > Page 3298 Crankshaft Position Sensor: Description and Operation Ignition Systems Crankshaft Position Sensor Typical Crankshaft Position (CKP) Sensor The crankshaft position (CKP) sensor (Figure 54) is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP sensor is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to a fixed reference (Figure 54) for the CKP sensor configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between teeth. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Page 3299 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Crankshaft Position (CKP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ The new CKP sensor needs to be touching the damper. The new sensor has wear tabs that will wear off after several engine revolutions. ^ Be sure the sensor wiring is routed away from the battery cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Specifications Ignition Switch Lock Cylinder: Specifications Lock Cylinder Housing Screws ............................................................................................................ .................................................... 22 Nm (16 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder-Functional Lock Cylinder Removal 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock cylinder. 3. To install, reverse the removal procedure. ^ Verify ignition switch lock cylinder operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 3306 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional Ignition Switch Lock Cylinder-Non-Functional Lock Cylinder Removal and Installation 1. NOTE: Make sure the front wheels are in the straight-ahead position. Disconnect the battery ground cable and wait at least one minute. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes and instructions in the steering wheel removal and installation procedure. Remove the steering wheel assembly. 3. Twist off the cap from the ignition switch cylinder. 4. NOTE: The lock cylinder is repaired by discarding the inoperative lock cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code oil the vehicle. Remove the ignition switch lock cylinder. ^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. ^ Use a 3/8-inch drill bit to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. ^ Remove and discard the ignition switch lock cylinder and clean the drill shavings from the steering column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 3307 5. Remove the bearing retainer. 6. Remove the bearing and gear. ^ Thoroughly clean all drill shavings from the steering column and inspect it for damage. 7. To install, reverse the removal procedure. ^ Install a new ignition switch lock cylinder. ^ Verify ignition switch lock cylinder operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations View 151-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3311 Connector View C109 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3312 Knock Sensor: Description and Operation Knock Sensor Knock Sensor (KS) The knock Sensor (KS) (Figure 34) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3313 Knock Sensor: Service and Repair REMOVAL 1. Disconnect the Knock Sensor (KS) electrical connector. 2. Remove the intake manifold. 3. Remove the KS. 1 Remove the bolt. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Technician Safety Information Fuel Pressure Test Port: Technician Safety Information WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Technician Safety Information > Page 3320 Fuel Pressure Test Port: Vehicle Damage Warnings CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 3321 Fuel Pressure Test Port: Description and Operation Pressure Test Point There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. ON VEHICLES NOT EQUIPPED WITH A SCHRADER VALVE, USE ROTUNDA FUEL PRESSURE TEST KIT #134-R0087 OR EQUIVALENT. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 3322 Fuel Pressure Test Port: Service and Repair REMOVAL WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Remove the fuel injection supply manifold. 2. Remove the two bolts, the pressure relief valve and the O-ring seals. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. NOTE: Lubricate the new O-ring seals with clean engine oil to aid installation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > With Automatic Transmission Idle Speed: Specifications With Automatic Transmission With Flex Fuel Hot Idle ................................................................................................................................................ ......................................................... 800 - 900 RPM With Gasoline Hot Idle ................................................................................................................................................ ......................................................... 760 - 780 RPM Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > With Automatic Transmission > Page 3327 Idle Speed: Specifications With Manual Transmission Hot Idle ................................................................................................................................................ ......................................................... 760 - 880 RPM Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Service and Repair Air Cleaner Housing: Service and Repair REMOVAL 1. Disconnect the air cleaner assembly. ^ Loosen the clamp and disconnect the outlet tube. ^ Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Remove the lower air cleaner assembly. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 3335 Fuel Pressure Release: Service and Repair Fuel Pressure Gauge SPECIAL TOOL(S) WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Disconnect the battery ground cable. 2. Remove the Schrader valve cap and attach the Fuel Pressure Gauge. 3. Open the manual valve on the Fuel Pressure Gauge slowly to relieve the fuel system pressure. This may drain fuel from the system. Drain the fuel into a suitable container. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 3336 Fuel Pressure Gauge Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Coil Terminal-To-Cylinder Relationship Firing order........................................................................................................................................... ..................................................................1-4-2-5-3-6 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 3340 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 05-10-3 > May > 05 > Interior - Accelerator Pedal Vibration at 1500-1800 RPM Ignition Cable: Customer Interest Interior - Accelerator Pedal Vibration at 1500-1800 RPM TSB 05-10-3 05/30/05 ACCELERATOR PEDAL VIBRATION/BUZZ AT 1500-1800 RPM FORD: 2001-2005 Explorer Sport Trac ISSUE Some 2001-2005 Explorer Sport Trac vehicles may exhibit the accelerator pedal vibrating or buzzing at 1500-1800 RPM. ACTION Ensure the accelerator cable and the hood release cables are not contacting the # 6 spark plug wire. Reposition cables as needed. Also, ensure that the accelerator cable is secure in the retention clip, and that the clip's spring tensioner is on top. Refer to Figure 1 (incorrect position) and Figure 2 (correct position). WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9A758 43 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 05-10-3 > May > 05 > Interior - Accelerator Pedal Vibration at 1500-1800 RPM > Page 3353 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 05-10-3 > May > 05 > Interior - Accelerator Pedal Vibration at 1500-1800 RPM Ignition Cable: All Technical Service Bulletins Interior - Accelerator Pedal Vibration at 1500-1800 RPM TSB 05-10-3 05/30/05 ACCELERATOR PEDAL VIBRATION/BUZZ AT 1500-1800 RPM FORD: 2001-2005 Explorer Sport Trac ISSUE Some 2001-2005 Explorer Sport Trac vehicles may exhibit the accelerator pedal vibrating or buzzing at 1500-1800 RPM. ACTION Ensure the accelerator cable and the hood release cables are not contacting the # 6 spark plug wire. Reposition cables as needed. Also, ensure that the accelerator cable is secure in the retention clip, and that the clip's spring tensioner is on top. Refer to Figure 1 (incorrect position) and Figure 2 (correct position). WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9A758 43 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 05-10-3 > May > 05 > Interior - Accelerator Pedal Vibration at 1500-1800 RPM > Page 3359 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 3360 Ignition Cable: Service Precautions CAUTION: ^ Spark plug wires must be connected correctly. Mark the spark plug wires before removing them. ^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. ^ Be sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifold. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 3361 Ignition Cable: Service and Repair Spark Plug Wire Remover SPECIAL TOOL(S) REMOVAL 1. Remove the right front tire. 2. Remove the right front fenderwell splash shield. 3. With a twisting motion, use the special tool to pull the spark plug wires from the right side of the engine. CAUTION: ^ Spark plug wires must be connected correctly. Mark the spark plug wires before removing them. ^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. 4. Lower the vehicle. 5. With a twisting motion, use the special tool to pull the spark plug wires from the left side of the engine. CAUTION: ^ Spark plug wires must be connected correctly. Mark the spark plug wires before removing them. ^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 3362 6. Squeeze the locking tabs and twist while pulling upward to remove the spark plug wires from the ignition coil. 7. Disconnect the spark plug wires from the separators and remove the spark plug wires. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Be sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifold. NOTE: Apply silicone dielectric compound to the inside of the spark plug and ignition coil boots of the spark plug wire. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 3363 Spark Plug Wire Remover Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Spark Plug: Specifications Gap Item....................................................................................................................................................... ..............................................................Specification Spark plug gap..................................................................................................................................... ....................................1.57-1.73 mm (0.061-0.068 in) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap > Page 3368 Spark Plug: Specifications Torque Item....................................................................................................................................................... ..............................................................Specification Spark plug............................................................................................................................................ .........................................................17 Nm (13 Lb-Ft) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3369 Spark Plug: Application and ID Item....................................................................................................................................................... ..............................................................Specification Spark plug type..................................................................................................................................... ..................................................................AGSF34FP Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3370 Spark Plug: Service and Repair REMOVAL 1. Remove the spark plug wires from the spark plugs. 2. Remove the spark plugs. NOTE: ^ Use compressed air to remove any foreign material in the spark plug well before removing the spark plugs. ^ If an original spark plug is reused, make sure it is installed in the same cylinder it was taken from. New spark plugs can be used in any cylinder. 3. Inspect the spark plugs. 4. Use a suitable spark plug gap tool to check and adjust the spark plug gap. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Pressure Limit Chart The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 3374 Compression Check: Testing and Inspection Compression Test-Compression Gauge Check 1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level and that the battery is correctly charged. Operate the vehicle until the engine is at normal operating temperature. Turn the ignition switch to the OFF position, then remove all the spark plugs. 2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the Compression Tester in the No. 1 cylinder. 4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position, and using the auxiliary starter switch, crank the engine a minimum of five compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Compression Test-Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Compression Test-Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. 2. If compression does not improve, valves are sticking or seating incorrectly. 3. If two adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 3375 Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is within 75 percent of the highest reading. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor > Component Information > Description and Operation Absolute Pressure Sensor: Description and Operation Thermal Manifold Absolute Pressure Sensor Thermal Manifold Absolute Pressure (TMAP) Sensor The Thermal Manifold Absolute Pressure Sensor (TMAP) (Figure 40) consists of a Manifold Absolute Pressure (MAP) sensor and an integrated thermistor. The thermistor part of the sensor is currently not being used. The MAP part of the sensor measures intake manifold air absolute pressure. The PCM uses information from the MAP sensor, Throttle Position (TP) sensor, mass air flow (MAF) sensor, engine coolant temperature (ECT) or cylinder head temperature (CHT) sensor and crankshaft position (CKP) sensor to determine how much exhaust gas is introduced into the intake manifold. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations View 151-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3383 Connector View C128 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3384 Mass Air Flow Sensor: Service Precautions CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3385 Mass Air Flow Sensor: Description and Operation Mass Air Flow Sensor Typical Mass Air Flow (MAF) Sensor Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire Terminals The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 35). If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio (Figure 36). This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3386 Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated intake air temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar, Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3387 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Loosen the air cleaner outlet tube clamp and position the tube aside. 3. Remove the four bolts and the MAF sensor. CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Description and Operation Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor Intake Air Temperature (IAT) The Intake Air Temperature (IAT) sensors (Figure 33) and integrated Mass Air Flow (MAF) type (Figure 36), are thermistor devices in which resistance changes with temperature The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of fuel, spark and MAF. The IAT sensor provides a quicker temperature change response time than the ECT or CHT sensor. Supercharged vehicles use (2) IAT sensors. Both sensors are thermistor type devices and operate as above. However, one is located before the supercharger at the air cleaner for standard OBD II/cold weather input, while a second sensor (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control border-line spark and to help determine intercooler efficiency. Currently two types of IAT2 sensors are used. A screw in type (Figure 33) and an integrated type, witch is part of the Thermal Manifold Absolute Pressure (TMAP) sensor (Figure 40). The TMAP sensor consists of a IAT thermistor and a Manifold Absolute Pressure (MAP) sensor. The thermistor portion of the TMAP is used for IAT2 function and operates in the same manner as a non-integrated IAT2. For additional information on the MAP portion of the TMAP, refer to the Thermal Manifold Absolute Pressure Sensor description and operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle Technical Service Bulletin # 03-3-5 Date: 030217 Engine Controls - No Start/Hard Start/Rough Idle Article No. 03-3-5 02/17/03 DRIVEABILITY - IDLE AIR CONTROL (IAC) VALVE DIAGNOSTIC SERVICE TIPS FORD: 2000-2003 TAURUS 2002 THUNDERBIRD 2000-2003 EXPLORER, RANGER 2001-2003 EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 2000-2002 LS MERCURY: 2000-2003 SABLE, MOUNTAINEER ISSUE Some vehicles, may exhibit drivability conditions. These may include: ^ No start Difficult to start Stall ^ Low idle ^ Rough idle ^ High idle ^ Hesitation/surge while accelerating or at steady speed These conditions may be intermittent with no Diagnostic Trouble Codes (DTC) and no Malfunction Indicator Lamp (MIL). In some cases DTC and MIL may be evident. ACTION Trouble cannot be identified with 95% of returned Idle Air Control (IAC) valves. The following procedure is supplemental information to normal diagnostics to facilitate accurate identification of malfunctioning valves. These symptoms would include engine stall, hard start, crank/no start, idling problems, and Idle Speed Control System related DTC's. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3399 If the service writer uses the worksheet (Figure 2) for all drivability concerns including stalls it will assist the technician making a correct repair the first time. Perform normal diagnostics. SERVICE INFORMATION NOTE Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3400 IT MAY NOT BE POSSIBLE TO DUPLICATE THE CUSTOMER CONCERN. ALTHOUGH THE CONDITION MAY NOT BE DUPLICATED, IT IS RECOMMENDED THAT ANY EVALUATION OF THE IAC VALVE BE DONE IN ACCORDANCE WITH THE FOLLOWING SERVICE PROCEDURE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 602300 603300, 607000, 607400, 607700, 608000, 608400, 611000, 618400, 619400, 698298 Disclaimer IAC Diagnostic Service Tips - General Never clean an IAC valve. Carburetor cleaners and other cleaning agents may temporarily repair the drivability concern, but the long-term functionality of the valve is compromised. For all drivability concerns, make certain the service writer obtains as much information as possible from the customer as to the conditions causing drivability concern. Attached is a drivability concern check off sheet (Figure 2) that if used, can help reduce the time required to diagnose a vehicle. NOTE IF THE ENGINE STALLED WHILE THE VEHICLE WAS IN GEAR AND MOVING THE POSSIBILITY OF THE IAC VALVE CAUSING THIS IS UNLIKELY UNLESS IT OCCURRED ON DECELERATION. Use the following Supplemental information for 3.0L 4V Duratec Engines, in the Taurus/Sable, and Lincoln LS. 1. Use the following conditions for the test described below: ^ Transmission in park ^ Engine temperature should be at least 190° F (88°C) ^ All accessories should be off steering wheel in the center position ^ EGVR and EVAPDUTY CYCLE at zero, if the vehicle has an EGR system ^ Short and long term fuel trims less than 15% ^ At stabilized engine speed (RPM) and temperature (hot idle) per the Powertrain Control Emission Diagnostics (PC/ED) manual, verify the IAC duty cycle is within reference values called out in the chart in this TSB. NOTE IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES. If the Duty Cycle is out of specification, proceed with the following steps: 1. Ensure that there is no purge flow. 2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is running and observe the IAC duty cycle and engine performance. Should abnormalities be observed, repair the harness as required. 3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times. If the duty cycle remains high, replace IAC valve. 4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC diagnostic service tip for DTC 1506 and other high idle concerns. Use the following Supplemental Information for the 3.9L Lincoln LS and Thunderbird. 1. Use the following conditions for the test described below: ^ Transmission in park Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3401 ^ Engine idle at approximately 650 RPM ^ Engine temperature should be at least 190° F (88° C) ^ All accessories and the engine cooling fan should be off ^ Steering wheel in the center position ^ EGRVR and EVAPDUTY CYCLE are zero ^ Short and long term fuel trims less than 15% NOTE IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES. NOTE IT IS EXTREMELY IMPORTANT TO CHECK THE IAC DUTY CYCLE WHEN THE RPM IS AT 650 RPM. EVEN 700 RPM IS TOO HIGH FOR CHECKING the IAC VALVE DUTY CYCLE UNDER THESE CONDITIONS. IF THE RPM IS OVER 650 RPM, MOMENTARILY OPENING AND CLOSING THE THROTTLE AND A SHORT EQUILIBRATION TIME WILL LOWER THE RPM. At stabilized engine speed and temperature, verify that the IAC duty cycle is between 27-36% with no purge flow (EVAPV duty cycle is 0%). If the Duty Cycle is out of specification, proceed with the following steps: 1. Ensure there is no purge flow. 2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is running and observe the IAC duty cycle and engine performance. Should abnormalities be observed, repair the harness as required. 3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times. If the duty cycle remains high, replace IAC valve. 4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC diagnostic service tip for DTC 1506 and other high idle concerns. NOTE IF THE ORIGINAL IAC VALVE WAS WITHIN DUTY CYCLE SPECIFICATION OR THE DUTY CYCLE REMAINS OUT OF SPECIFICATIONS AFTER IAC VALVE REPLACEMENT FURTHER DIAGNOSTICS ARE REQUIRED TO ADDRESS THE CUSTOMER CONCERN. Use the following Supplemental Information for 4.0L SOHC Engines In the Ranger, Explorer, Mountaineer, Explorer Sport and Explorer Sport Trac. If no DTC's present check the following items in this order before examining the IAC valve: ^ BARO Hz reading - Refer to Barometric Pressure Chart listed in this TSB ^ Battery and fuse box power lead ^ Ground wire attachments ^ Wiring (wiggle test) ^ PCM voltage ^ Vacuum leaks Examine AC valve under these conditions: ^ PCM updated to the latest available calibration ^ Transmission in park ^ Warm stabilized vehicle with engine temperature at least 190° F (88° C) ^ All accessories and cooling fan sh6uld be off Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3402 ^ Steering wheel in the center position ^ EGVR and EVAPDC at zero, if the vehicle has an EGR system ^ Short and long term fuel trims (less than 15) Perform the following steps in order: 1. Using either NGS or WDS bring up the following PIDS: IACTRIM, IACKAM2, IACKAM3. 2. Allow vehicle to idle until the IACTRIM PID is 0. NOTE IACTRIM ALWAYS TRIES TO GO TO 0. WHEN MOVING TOWARDS 0, THE IACKAM2 PID SHOULD BE CHANGING. IF IACKAM3 IS CHANGING, THEN THE AIR CONDITIONING SHOULD BE TURNED OFF. 3. If IACKAM2 is between -0.35 and +0.35 with IACTRIM=0, then the valve is operating properly at idle. The remainder of this TSB will help diagnose true root cause. 4. If IACKAM2 is not between -0.35 and +0.35, it is highly likely that the engine idle system (to include the throttle body and air intake system) -is not operating properly. NOTE FOR ALL VEHICLES PLEASE RECORD THE OBSERVED IAC DUTY CYCLE AND ENGINE RPM IN THE WARRANTY CLAIMS COMMENTS FOR THIS DIAGNOSTIC. IAC Diagnostic Service Tips - DTC 1506 (IAC Over Speed Error) and other High Idle Concerns: ^ There are two primary causes of high idle: 1. Damaged IAC valves and 2. Vacuum leaks ^ AC valves can be damaged from engine induction backfires. Many times the customer may not notice the induction backfire but will notice the high idle afterwards. Indications of valve damage can be a shiny, almost polished appearance in the interior of the valve and a dislocated Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3403 pintle. An IAC valve damaged by backfire should be replaced. Refer to Figure 1. ^ Inspect PCV system for leaks especially looking for cracks along any rubber elbow joints; also verify that the correct PCV valve is installed. ^ Inspect for vacuum hoses loose or disconnected from intended ports and connections. Induction backfire can loosen or disconnect vacuum hoses. ^ Two indicators can help you identify if a vacuum leak is present, even if the engine RPM appear normal in the service bay. If the duty cycle is below specification that is indicative that the engine is receiving too much air (from a vacuum leak) and the PCM is ordering the valve to close up to restrict flow. Another indication is fuel trim. Record the long term and short term fuel trim PIDS (LONGFT1, LONGFT2, SHORTFT1, etc.), if short term fuel trims are high (above specification) this is a possible indication of a vacuum leak, making the engine run lean, and the PCM is attempting to compensate. IAC Diagnostic Service Tips - DTC 1507 (IAC Under Speed Error) and Other Low Idle Concerns: ^ An under speed error may not necessarily be a fault with the IAC valve. A large friction load on the engine or obstruction in the air intake system could also reduce the engine RPMs. ^ There are four possible sources of friction load that can contribute to under speed error or low idle concerns. 1. Power Steering Load 2. Air Conditioning Load 3. Electrical Load 4. Automatic Transmission Torque Converter Load EAC Diagnostic Service Tips - Rough Idle Concerns: ^ Rough idle concerns are often a result of a lean running condition ^ Another possible cause is contamination build up on the MAF sensor EAC Diagnostic Service Tips - Engine Hard Start/Engine Crank-No Start ^ While performing diagnostics, the technician should ensure that the fuel system is working correctly for all engines with hard start/crank no-start complaints. ^ When diagnosing a mechanical return less fuel system, the following correction to the PC/ED pinpoint HC (4) diagnostic procedure should be used when performing the KEOE fuel pressure test: ^ Perform the KOEO fuel pressure test as specific in the PC/ED manual. ^ The fuel pressure should drop off no more than 10 psi from maximum pressure (no lower than 55 psi for a 65 psi max system or no lower than 45 psi for a 55 psi max system) within 5 minutes of the start of the test. ^ The fuel pressure should drop off to no less than 30 psi within 30 minutes of the start of the test. ^ For greatest accuracy, the service technician should read the fuel pressure as soon as possible after pump shut off, no more than 5 minutes after the start of the test. NOTE RETURNABLE AND ELECTRONIC RETURN LESS SYSTEMS SHOULD ALSO BE DIAGNOSED USING THE PROCEDURES LISTED FOR THEM IN PINPOINT TEST HC. IAC Diagnostic Service Tips - High Idle RPM at Start Up: ^ Most engines will have a temporary high idle at engine start up to allow for catalyst light off. If DTC 1506 is not present, this indicates that there is no fault present with the IAC. ^ A vehicle with very low odometer miles, may exhibit a higher than normal temporary startup fast idle (1600-2500 RPM that decreases slowly). No Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3404 repairs should be attempted because this is a normal temporary PCM calibration strategy to prevent spark plug fouling during plant/transportation operation. The calibration will permanently revert to its normal strategy after the PCM has seen its first 4 miles of continuous drive cycle. A brand new vehicle may accumulate some mileage without turning this strategy off if the drive cycle has been below 4 miles at a time. IAC Diagnostic Service Tips - EAC Valve Noise Issues For IAC valve noise concerns check for obstructed or potentially damaged IAC valve from backfire. NOTE Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3405 ON SOME NEWER MODEL YEAR VEHICLES THE REACTION SPEED OF THE EAC VALVE IS FAST ENOUGH THAT IT MIGHT MAKE A "POPPING" SOUND AS IT REACTS TO A LARGE IDLE LOAD. THIS IS A NORMAL CHARACTERISTIC AND NO ATTEMPTS SHOULD BE MADE IN AN EFFORT TO MODIFY THE PERFORMANCE OF THE IAC VALVE. IF POSSIBLE, COMPARE AGAINST A LIKE VEHICLE. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/-1 in.Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE, WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle Technical Service Bulletin # 03-3-5 Date: 030217 Engine Controls - No Start/Hard Start/Rough Idle Article No. 03-3-5 02/17/03 DRIVEABILITY - IDLE AIR CONTROL (IAC) VALVE DIAGNOSTIC SERVICE TIPS FORD: 2000-2003 TAURUS 2002 THUNDERBIRD 2000-2003 EXPLORER, RANGER 2001-2003 EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 2000-2002 LS MERCURY: 2000-2003 SABLE, MOUNTAINEER ISSUE Some vehicles, may exhibit drivability conditions. These may include: ^ No start Difficult to start Stall ^ Low idle ^ Rough idle ^ High idle ^ Hesitation/surge while accelerating or at steady speed These conditions may be intermittent with no Diagnostic Trouble Codes (DTC) and no Malfunction Indicator Lamp (MIL). In some cases DTC and MIL may be evident. ACTION Trouble cannot be identified with 95% of returned Idle Air Control (IAC) valves. The following procedure is supplemental information to normal diagnostics to facilitate accurate identification of malfunctioning valves. These symptoms would include engine stall, hard start, crank/no start, idling problems, and Idle Speed Control System related DTC's. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3411 If the service writer uses the worksheet (Figure 2) for all drivability concerns including stalls it will assist the technician making a correct repair the first time. Perform normal diagnostics. SERVICE INFORMATION NOTE Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3412 IT MAY NOT BE POSSIBLE TO DUPLICATE THE CUSTOMER CONCERN. ALTHOUGH THE CONDITION MAY NOT BE DUPLICATED, IT IS RECOMMENDED THAT ANY EVALUATION OF THE IAC VALVE BE DONE IN ACCORDANCE WITH THE FOLLOWING SERVICE PROCEDURE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 602300 603300, 607000, 607400, 607700, 608000, 608400, 611000, 618400, 619400, 698298 Disclaimer IAC Diagnostic Service Tips - General Never clean an IAC valve. Carburetor cleaners and other cleaning agents may temporarily repair the drivability concern, but the long-term functionality of the valve is compromised. For all drivability concerns, make certain the service writer obtains as much information as possible from the customer as to the conditions causing drivability concern. Attached is a drivability concern check off sheet (Figure 2) that if used, can help reduce the time required to diagnose a vehicle. NOTE IF THE ENGINE STALLED WHILE THE VEHICLE WAS IN GEAR AND MOVING THE POSSIBILITY OF THE IAC VALVE CAUSING THIS IS UNLIKELY UNLESS IT OCCURRED ON DECELERATION. Use the following Supplemental information for 3.0L 4V Duratec Engines, in the Taurus/Sable, and Lincoln LS. 1. Use the following conditions for the test described below: ^ Transmission in park ^ Engine temperature should be at least 190° F (88°C) ^ All accessories should be off steering wheel in the center position ^ EGVR and EVAPDUTY CYCLE at zero, if the vehicle has an EGR system ^ Short and long term fuel trims less than 15% ^ At stabilized engine speed (RPM) and temperature (hot idle) per the Powertrain Control Emission Diagnostics (PC/ED) manual, verify the IAC duty cycle is within reference values called out in the chart in this TSB. NOTE IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES. If the Duty Cycle is out of specification, proceed with the following steps: 1. Ensure that there is no purge flow. 2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is running and observe the IAC duty cycle and engine performance. Should abnormalities be observed, repair the harness as required. 3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times. If the duty cycle remains high, replace IAC valve. 4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC diagnostic service tip for DTC 1506 and other high idle concerns. Use the following Supplemental Information for the 3.9L Lincoln LS and Thunderbird. 1. Use the following conditions for the test described below: ^ Transmission in park Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3413 ^ Engine idle at approximately 650 RPM ^ Engine temperature should be at least 190° F (88° C) ^ All accessories and the engine cooling fan should be off ^ Steering wheel in the center position ^ EGRVR and EVAPDUTY CYCLE are zero ^ Short and long term fuel trims less than 15% NOTE IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES. NOTE IT IS EXTREMELY IMPORTANT TO CHECK THE IAC DUTY CYCLE WHEN THE RPM IS AT 650 RPM. EVEN 700 RPM IS TOO HIGH FOR CHECKING the IAC VALVE DUTY CYCLE UNDER THESE CONDITIONS. IF THE RPM IS OVER 650 RPM, MOMENTARILY OPENING AND CLOSING THE THROTTLE AND A SHORT EQUILIBRATION TIME WILL LOWER THE RPM. At stabilized engine speed and temperature, verify that the IAC duty cycle is between 27-36% with no purge flow (EVAPV duty cycle is 0%). If the Duty Cycle is out of specification, proceed with the following steps: 1. Ensure there is no purge flow. 2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is running and observe the IAC duty cycle and engine performance. Should abnormalities be observed, repair the harness as required. 3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times. If the duty cycle remains high, replace IAC valve. 4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC diagnostic service tip for DTC 1506 and other high idle concerns. NOTE IF THE ORIGINAL IAC VALVE WAS WITHIN DUTY CYCLE SPECIFICATION OR THE DUTY CYCLE REMAINS OUT OF SPECIFICATIONS AFTER IAC VALVE REPLACEMENT FURTHER DIAGNOSTICS ARE REQUIRED TO ADDRESS THE CUSTOMER CONCERN. Use the following Supplemental Information for 4.0L SOHC Engines In the Ranger, Explorer, Mountaineer, Explorer Sport and Explorer Sport Trac. If no DTC's present check the following items in this order before examining the IAC valve: ^ BARO Hz reading - Refer to Barometric Pressure Chart listed in this TSB ^ Battery and fuse box power lead ^ Ground wire attachments ^ Wiring (wiggle test) ^ PCM voltage ^ Vacuum leaks Examine AC valve under these conditions: ^ PCM updated to the latest available calibration ^ Transmission in park ^ Warm stabilized vehicle with engine temperature at least 190° F (88° C) ^ All accessories and cooling fan sh6uld be off Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3414 ^ Steering wheel in the center position ^ EGVR and EVAPDC at zero, if the vehicle has an EGR system ^ Short and long term fuel trims (less than 15) Perform the following steps in order: 1. Using either NGS or WDS bring up the following PIDS: IACTRIM, IACKAM2, IACKAM3. 2. Allow vehicle to idle until the IACTRIM PID is 0. NOTE IACTRIM ALWAYS TRIES TO GO TO 0. WHEN MOVING TOWARDS 0, THE IACKAM2 PID SHOULD BE CHANGING. IF IACKAM3 IS CHANGING, THEN THE AIR CONDITIONING SHOULD BE TURNED OFF. 3. If IACKAM2 is between -0.35 and +0.35 with IACTRIM=0, then the valve is operating properly at idle. The remainder of this TSB will help diagnose true root cause. 4. If IACKAM2 is not between -0.35 and +0.35, it is highly likely that the engine idle system (to include the throttle body and air intake system) -is not operating properly. NOTE FOR ALL VEHICLES PLEASE RECORD THE OBSERVED IAC DUTY CYCLE AND ENGINE RPM IN THE WARRANTY CLAIMS COMMENTS FOR THIS DIAGNOSTIC. IAC Diagnostic Service Tips - DTC 1506 (IAC Over Speed Error) and other High Idle Concerns: ^ There are two primary causes of high idle: 1. Damaged IAC valves and 2. Vacuum leaks ^ AC valves can be damaged from engine induction backfires. Many times the customer may not notice the induction backfire but will notice the high idle afterwards. Indications of valve damage can be a shiny, almost polished appearance in the interior of the valve and a dislocated Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3415 pintle. An IAC valve damaged by backfire should be replaced. Refer to Figure 1. ^ Inspect PCV system for leaks especially looking for cracks along any rubber elbow joints; also verify that the correct PCV valve is installed. ^ Inspect for vacuum hoses loose or disconnected from intended ports and connections. Induction backfire can loosen or disconnect vacuum hoses. ^ Two indicators can help you identify if a vacuum leak is present, even if the engine RPM appear normal in the service bay. If the duty cycle is below specification that is indicative that the engine is receiving too much air (from a vacuum leak) and the PCM is ordering the valve to close up to restrict flow. Another indication is fuel trim. Record the long term and short term fuel trim PIDS (LONGFT1, LONGFT2, SHORTFT1, etc.), if short term fuel trims are high (above specification) this is a possible indication of a vacuum leak, making the engine run lean, and the PCM is attempting to compensate. IAC Diagnostic Service Tips - DTC 1507 (IAC Under Speed Error) and Other Low Idle Concerns: ^ An under speed error may not necessarily be a fault with the IAC valve. A large friction load on the engine or obstruction in the air intake system could also reduce the engine RPMs. ^ There are four possible sources of friction load that can contribute to under speed error or low idle concerns. 1. Power Steering Load 2. Air Conditioning Load 3. Electrical Load 4. Automatic Transmission Torque Converter Load EAC Diagnostic Service Tips - Rough Idle Concerns: ^ Rough idle concerns are often a result of a lean running condition ^ Another possible cause is contamination build up on the MAF sensor EAC Diagnostic Service Tips - Engine Hard Start/Engine Crank-No Start ^ While performing diagnostics, the technician should ensure that the fuel system is working correctly for all engines with hard start/crank no-start complaints. ^ When diagnosing a mechanical return less fuel system, the following correction to the PC/ED pinpoint HC (4) diagnostic procedure should be used when performing the KEOE fuel pressure test: ^ Perform the KOEO fuel pressure test as specific in the PC/ED manual. ^ The fuel pressure should drop off no more than 10 psi from maximum pressure (no lower than 55 psi for a 65 psi max system or no lower than 45 psi for a 55 psi max system) within 5 minutes of the start of the test. ^ The fuel pressure should drop off to no less than 30 psi within 30 minutes of the start of the test. ^ For greatest accuracy, the service technician should read the fuel pressure as soon as possible after pump shut off, no more than 5 minutes after the start of the test. NOTE RETURNABLE AND ELECTRONIC RETURN LESS SYSTEMS SHOULD ALSO BE DIAGNOSED USING THE PROCEDURES LISTED FOR THEM IN PINPOINT TEST HC. IAC Diagnostic Service Tips - High Idle RPM at Start Up: ^ Most engines will have a temporary high idle at engine start up to allow for catalyst light off. If DTC 1506 is not present, this indicates that there is no fault present with the IAC. ^ A vehicle with very low odometer miles, may exhibit a higher than normal temporary startup fast idle (1600-2500 RPM that decreases slowly). No Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3416 repairs should be attempted because this is a normal temporary PCM calibration strategy to prevent spark plug fouling during plant/transportation operation. The calibration will permanently revert to its normal strategy after the PCM has seen its first 4 miles of continuous drive cycle. A brand new vehicle may accumulate some mileage without turning this strategy off if the drive cycle has been below 4 miles at a time. IAC Diagnostic Service Tips - EAC Valve Noise Issues For IAC valve noise concerns check for obstructed or potentially damaged IAC valve from backfire. NOTE Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3417 ON SOME NEWER MODEL YEAR VEHICLES THE REACTION SPEED OF THE EAC VALVE IS FAST ENOUGH THAT IT MIGHT MAKE A "POPPING" SOUND AS IT REACTS TO A LARGE IDLE LOAD. THIS IS A NORMAL CHARACTERISTIC AND NO ATTEMPTS SHOULD BE MADE IN AN EFFORT TO MODIFY THE PERFORMANCE OF THE IAC VALVE. IF POSSIBLE, COMPARE AGAINST A LIKE VEHICLE. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/-1 in.Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE, WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Diagrams Connector View C278 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Description and Operation > Brake Pedal Position Switch Brake Signal: Description and Operation Brake Pedal Position Switch Brake Pedal Position Switch Typical Brake Pedal Position Switch The Brake Pedal Position (BPP) switch (Figure 21) is used by the PCM to disengage the transmission torque converter clutch and on some applications as an input to the idle speed control for idle quality and for vehicle speed control deactivation. On most applications the BPP switch is hard wired to the PCM and supplies battery positive voltage (B+) when the vehicle brake pedal is applied. On other applications the BPP switch signal is broadcast over the SCP link via another module to be received by the PCM. On applications where the BPP switch is hard wired to the PCM and stoplamp circuit, if all stoplamp bulbs are burned out (open), high voltage is present at the PCM due to a pull-up resistor in the PCM. This provides fail-safe operation in the event the circuit to the stoplamp bulbs has failed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Description and Operation > Brake Pedal Position Switch > Page 3423 Brake Signal: Description and Operation Brake Pressure Applied Brake Deactivator Switch Brake Pressure Applied Brake Deactivator Switch The Brake Pressure Applied (BPA) switch also sometimes called the brake deactivator switch for vehicle speed control deactivation. Is a normally closed switch, witch supplies battery positive voltage (B+) to the PCM when the brake pedal is NOT applied. When the brake pedal is depressed, the normally closed switch will open and power is removed from the PCM. On some applications the normally closed BPA switch along with the normally open brake pedal position (BPP) switch are used for a brake rationality test within the PCM. The PCM misfire monitor profile learn function can be disable if a brake switch failure occurs. If one or both brake pedal inputs to the PCM did not change states when they were expected to a diagnostic trouble code P1572 can be set by the PCM strategy. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations View 151-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3427 Connector View C180 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > PCM Input Camshaft Position Sensor: Description and Operation PCM Input Camshaft Position Sensor The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No.1 is on its compression stroke. A signal is then sent to the powertrain control module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctance Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22) and the two pin connector variable reluctance sensor (Figure 23). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > PCM Input > Page 3430 Camshaft Position Sensor: Description and Operation Ignition Systems Camshaft Position Sensor Camshaft Position (CMP) Sensor The camshaft position sensor (Figure 55) used by COP Integrated EI system is a magnetic transducer mounted on the engine front cover adjacent to the camshaft. By monitoring a target on the camshaft sprocket, the CMP sensor identifies cylinder one to the PCM. The COP Integrated EI system uses this information to synchronize the firing of the individual coils. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 3431 Camshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams Connector View C257 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams > Page 3435 Clutch Switch: Description and Operation Clutch Pedal Position Switch Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch (Figure 24) is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Computers and Control Circuit Diode > Component Information > Diagrams Connector View C1018 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations View 151-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Engine Coolant Temperature (ECT) Sender Connector View C1061 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Engine Coolant Temperature (ECT) Sender > Page 3444 Connector View C1064 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 3445 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Engine Coolant Temperature (ECT) Sensor The Engine Coolant Temperature (ECT) sensor (Figure 27) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. The ECT sensor is similar in construction to the IAT sensor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 3446 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector. 2. Remove the retaining clip and the ECT sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations View 151-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3450 Connector View C101 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > PCM Input Crankshaft Position Sensor: Description and Operation PCM Input Crankshaft Position Sensor (Integrated Ignition Systems) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the powertrain control module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to fixed reference (Figure 25). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > PCM Input > Page 3453 Crankshaft Position Sensor: Description and Operation Ignition Systems Crankshaft Position Sensor Typical Crankshaft Position (CKP) Sensor The crankshaft position (CKP) sensor (Figure 54) is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP sensor is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to a fixed reference (Figure 54) for the CKP sensor configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between teeth. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Page 3454 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Crankshaft Position (CKP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ The new CKP sensor needs to be touching the damper. The new sensor has wear tabs that will wear off after several engine revolutions. ^ Be sure the sensor wiring is routed away from the battery cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations View 151-9 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions Data Link Connector: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. NOTE: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3460 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number or the component name in one of the the A-Z Component Lists, the Component Location description for that component can easily be found. See: Locations/Component Locations/A-Z Component List Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3461 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3462 the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3463 that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3464 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3465 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3466 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3467 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3468 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3469 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3470 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3471 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3472 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3473 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3474 Systems Overview Wire Color Code Identification Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3475 OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3476 Data Link Connector: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3477 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3478 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3479 Connector View C251 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3480 Data Link Connector: Electrical Diagrams Diagram 14-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3481 Diagram 14-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3490 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3491 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3492 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures Powertrain Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 3498 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 3499 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3504 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3505 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3506 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures Powertrain Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 3512 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 3513 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3514 View 151-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3515 Powertrain Control Module: Diagrams Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3516 Part 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3517 Powertrain Control Module: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the Powertrain Control Module (PCM) electrical connector. 3. Remove the nuts and the PCM cover. 4. Remove the PCM. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor Cylinder Head Temperature (CHT) Sensor The Cylinder Head Temperature (CHT) sensor (Figure 26) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The cylinder head temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. For additional information, refer to Powertrain Control Software for Fail-Safe Cooling Strategy details. See: Description and Operation/Powertrain Control Software Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Pump Signal > Component Information > Description and Operation Fuel Pump Signal: Description and Operation Fuel Pump Monitor Applications Using a Fuel Pump Relay for Fuel Pump On/Off Control The Fuel Pump Monitor (FPM) circuit is spliced into the Fuel Pump Power (FP PWR) circuit and is used by the PCM for diagnostic purposes. The PCM sources a low current voltage down the FPM circuit. With the fuel pump off, this voltage is pulled low by the path to ground through the fuel pump. With the fuel pump off and the FPM circuit low, the PCM can verify that the FPM circuit and the FP PWR circuit are complete from the FPM splice through the fuel pump to ground. This also confirms that the FP PWR or FPM circuits are not shorted to power. With the fuel pump on, voltage is now being supplied from the fuel pump relay to the FP PWR and FPM circuits. With the fuel pump on and the FPM circuit high, the PCM can verify that the FP PWR circuit from the fuel pump relay to the FPM splice is complete. It can also verify that the fuel pump relay contacts are closed and there is a B+ supply to the fuel pump relay Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions Fuel Tank Pressure Sensor: Service Precautions CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions > Page 3527 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure Sensor Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The Fuel Tank Pressure (FTP) sensor (Figure 97) or inline fuel tank pressure (FTP) sensor (Figure 98) is used to measure the fuel tank pressure during the EVAP monitor test on vehicles equipped with the Running Loss-type system. Also, it is used to control excessive fuel tank pressure by forcing the system to purge. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions > Page 3528 Fuel Tank Pressure Sensor: Service and Repair REMOVAL 1. Remove the fuel tank. 2. Remove the fuel tank pressure sensor. 1 Disconnect the electrical connector. 2 Press down and rotate the fuel tank pressure sensor counterclockwise and remove it from the fuel tank. CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. INSTALLATION 1. To install, reverse removal procedure. ^ Leak test. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Evaporative Emission System Leak Test ^ Carry out the evaporative emissions repair verification drive cycle. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Evaporative Emission Repair Verification Drive Cycle Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams Connector View C1066 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Page 3532 Idle Air Control Valve: Description and Operation Idle Air Control Valve Nippondenso Idle Air Control (IAC) Valve Assembly Hitachi Idle Air Control (IAC) Valve Assembly With Vent/Filter The idle air control (IAC) valve assembly (Figure 117) and (Figure 118) controls engine idle speed and provides a dash pot function. The IAC valve assembly meters intake air around the throttle plate through a bypass within the IAC valve assembly and throttle body. The PCM determines the desired idle speed or bypass air and signals the IAC valve assembly through a specified duty cycle. The IAC valve responds by positioning the IAC valve to control the amount of bypassed air. The PCM monitors engine rpm and increases or decreases the IAC duty cycle in order to achieve the desired rpm. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Page 3533 Hitachi Idle Air Control (IAC) Valve Assembly With Air-Assist Injectors On applications with air-assisted injectors, the AC valve (Figure 119) also supplies a small amount of air into the path of the fuel injectors. The jet of air causes an increase in fuel atomization at low speed and light load conditions. NOTE: The IAC Valve Assembly is NOT ADJUSTABLE and CANNOT BE CLEANED. The IAC valve (part of throttle body assembly) has an internal diode on some applications. If the internal diode is measured in crossed terminal position with a digital multimeter, there will be an incorrect or negative reading. It is important that the mating component and harness connectors correctly oriented. Diagnostic procedures emphasize this importance. The PCM uses the IAC valve assembly to control: ^ No touch start ^ Cold engine fast idle for rapid warm-up ^ Idle (corrects for engine load) ^ Stumble or stalling on deceleration (provides a dash pot function) ^ Over-temperature idle boost. ^ Air Assist to Injectors. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Page 3534 Idle Air Control Valve: Service and Repair REMOVAL 1. Remove the accelerator control snow shield. 2. Disconnect the electrical connector, and remove the bolts and the Idle Air Control (IAC) valve. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Specifications Module Communication Network: Specifications Heat shrink tube overlap....................................................................................................................... ......................................................12.7 mm (0.5 inch) Wire insulation removal length (twist side)...... ..........................................................................................................................................37.2 mm (1.5 inch) Wire insulation removal length (receiving side).......................................................................................................................................19.5 mm (0.75 inch) Raychem SCT(R) heat shrink tubing, Motorcraft part number WT-5627....................................................................................................ESB-M99D56-A2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions Module Communication Network: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. NOTE: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3540 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number or the component name in one of the the A-Z Component Lists, the Component Location description for that component can easily be found. See: Locations/Component Locations/A-Z Component List Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3541 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3542 the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3543 that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3544 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3545 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3546 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3547 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3548 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3549 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3550 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3551 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3552 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3553 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3554 Systems Overview Wire Color Code Identification Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3555 OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3556 Module Communication Network: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3557 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3558 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3559 Module Communication Network: Electrical Diagrams Diagram 14-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3560 Diagram 14-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Description and Operation > Description and Operation Module Communication Network: Description and Operation The module communications network consists of the following items: ^ Generic Electronics Module (GEM) ^ Standard Corporate Protocol (SCP) communications network ^ International Standards Organization (ISO) communications network ^ Powertrain Control Module (PCM) ^ Anti-lock Brake Module (ABS) ^ Restraint Control Module (RCM) ^ central security module ^ Four-Wheel Drive (4WD) control module (if equipped) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Description and Operation > Description and Operation > Page 3563 Module Communication Network: Description and Operation Principles and Operation The vehicle has two module communications networks. The Standard Corporate Protocol (SCP), which is an unshielded twisted pair cable (data bus plus, circuit 914 [TN/OG] and data bus minus, circuit 915 [PK/LB]); and the International Standards Organization (ISO) 9141 network which is a single wire (circuit 70 [LB/WH]). The diagnostic tool can connect to both networks through the Data Link Connector (DLC). This makes diagnosis and testing of these systems easier by allowing one smart tester to be able to diagnose and control any module on the two networks from one connector. The DLC can be found under the instrument panel between the steering column and the radio. The SCP communication network will remain operational even with the severing of one of the bus wires. Communications will also continue if one of the bus wires is shorted to ground or voltage, or if some, but not all, termination resistors are lost. The ISO 9141 communication network does not permit inter-module communication. When the diagnostic tool communicates to modules on the ISO 9141 communication network, the diagnostic tool must ask for all information; the modules cannot initiate communications. Unlike the SCP, the ISO 9141 communication network will not function if the wire is shorted to ground or battery voltage. Also, if one of the modules on the ISO 9141 communication network loses power or shorts internally, communications to that module will fail. There is one module linked to the SCP communication network and five modules linked to the ISO 9141 communication network. The Powertrain Control Module (PCM) is on the SCP communication network. The PCM controls the engine for better fuel economy, emissions control and failure mode detection and storage. The Restraint Control Module (RCM) is on the ISO 9141 communication network. The RCM controls the deployment of the air bags based on sensor input. The Generic Electronic Module (GEM) is on the ISO 9141 communication network. The GEM controls a variety of systems: ^ windshield wipers ^ courtesy lamps ^ warning chimes ^ interior lamps ^ exterior lamps ^ power windows For additional GEM information, refer to Multifunction Electronic Control Module (General Module). The central security module is on the ISO 9141 communication network. The central security module controls the keyless remote entry of the vehicle. The Anti-lock Brake Control (ABS) module is on the ISO 9141 communication network. The ABS module controls the brake pressure to the four wheels to keep the vehicle under control while braking. The Four-Wheel Drive (4WD) control module is on the ISO 9141 communications network. The 4WD module controls all four-wheel drive functions including the 4WDLOW and 4WDHIGH indicator lamps. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Description and Operation > Description and Operation > Page 3564 Module Communication Network: Description and Operation Principles of Operation Some modules must be programmed as part of the repair procedure. If this procedure is not followed the module will not function correctly and may set a number of Diagnostic Trouble Codes (DTCs), including B2477 or P1639, which indicate that some necessary data has not been programmed into the module. Modules that need programming should not be transferred between vehicles. In most cases the parameter values or settings are unique to that vehicle, and if not set correctly will cause malfunctions or faults. Some programmable parameters, such as belt minder on/off, can be changed from the factory setting at the customer's request. WDS will automatically attempt to retrieve the module configuration information from all modules, and from a backup location in the Powertrain Control Module (PCM) when Vehicle ID is carried out. If the module and the PCM do not contain correct information the diagnostic tool will either request "As Built" data or display a list of items that you will need to manually configure. The diagnostic tool will program the module based on the data you enter. There are three different methods that are used for module programming: ^ Programmable Module Installation (PMI) ^ calibration update ^ programmable parameters Some modules do not support all three methods. Programmable Module Installation (PMI) The programmable module installation (PMI) method is used when a new programmable module is installed on the vehicle. It is no longer necessary to command the diagnostic tool to gather module option content from the old module. The diagnostic tool automatically obtains any available module option content information from the old module during the Vehicle ID routine that runs when the diagnostic tool is initially connected to the vehicle. It is important that you connect WDS to the vehicle and allow it to identify the vehicle and obtain configuration data prior to removing any modules. Calibration Update Calibration update is used to install a new calibration and strategy into a module. The updates are usually issued to fix a concern in the module software and would normally be addressed by a Technical Service Bulletin (TSB). This method has been used by the PCM for several years. Other modules will be adopting this strategy as well. Programmable Parameters This method is used to configure parameters that can be modified in repair. These are typically at the preference of the customer. Not all features controlled by the module are listed in this configuration method. Refer to the Module Configuration Index for a list of features by system. If a module that has been modified using programmable parameters needs to be installed, the PMI procedure will maintain the parameters in their altered state if WDS is able to communicate with the old module during Vehicle ID. Otherwise you may need to use programmable parameters to return them to the altered state. Vehicle Identification (VID) Block Some PCMs contain a memory area called a vehicle identification (VID) block. The VID block is used to store backup data for each programmable module, as well as powertrain configuration information. If the diagnostic tool cannot retrieve module option content information from the suspect module, the diagnostic tool will attempt to extract backup information from the PCM's VID block. The PCM VID block contains the factory settings for the configurable modules unless the PCM is flashed with a new calibration, in which case some PCM parameters may be modified. As-Built Data Center The As-Built Data Center maintains a record of the vehicle configuration in a database. The vehicles VIN is necessary to obtain this information. The As-Built Data Center records the applicable module configurations stored in each module before the vehicle leaves the factory. The As-Built Data Center will always reflect the original build of the vehicle as it left the factory. Only contact the As-Built Data Center when directed to do so by the diagnostic tool. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network Module Communication Network: Testing and Inspection Module Communications Network Initial Inspection 1. Verify the customer concern. 2. Visually inspect the following for obvious signs of electrical damage: VISUAL INSPECTION CHART Electrical ^ Central Junction Box (CJB) fuse 17 (20A) ^ Damaged wiring harness ^ Loose or corroded connectors 3. If the concern remains after the inspection, connect the diagnostic tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. If the diagnostic tool still does not communicate with the vehicle, go to Pinpoint Test I. See: Pinpoint Tests/Pinpoint Tests/Test I: No Module/Network Communication 4. Go to Pinpoint Test PC. See: Pinpoint Tests/Pinpoint Test PC (Precheck) PC1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3567 A1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3568 A2 - A3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3569 B1 - B3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3570 B3 C1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3571 C2 - C3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3572 D1 - D3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3573 D3 E1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3574 E2 - E3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3575 F1 - F2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3576 F2 - F3 Test G: No Module/Network Communication - ISO 9141 Network Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3577 G1 - G3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3578 G3 - G4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3579 G5 G6 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3580 G7 - G8 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3581 G9 - G11 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3582 G11 - G12 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3583 G13 - G14 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3584 G14 - G16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3585 G16 - G17 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3586 G17 - G18 Test H: No SCP Network Communication Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3587 H1 - H3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3588 H4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3589 H5 - H6 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3590 H6 I1 - I2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3591 I2 - I4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3592 Symptom Chart, Part 1 Symptom Chart, Part 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3593 Module Communication Network: Testing and Inspection Module Configuration Configurable Modules The vehicle contains the following modules that are configurable: ^ Anti-lock Brake (ABS) module (if equipped) ^ Generic Electronic Module (GEM) ^ central security module (if equipped) Initial Inspection 1. Visually inspect for obvious signs of electrical damage. Refer to the chart: VISUAL INSPECTION CHART Electrical ^ Wiring harness ^ Connectors Programmable Parameters Index Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Page 3594 Module Communication Network: Service and Repair COMMUNICATION CIRCUIT WIRING REPAIR Heat Gun SPECIAL TOOL(S) 1. Disconnect the battery ground cable. 2. Strip the wires. 3. Solder the wires. 1 Install the heat shrink tube. 2 Twist the wires together. 3 Solder the wires together. NOTE: Use Rosin Core Mildly Activated (RMA) solder, not acid core solder. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Page 3595 4. Bend the wires back in a straight line. NOTE: Wait for the solder to cool before moving the wires. 5. Position the (A) heat shrink tube over the (B) wire repair. ^ Overlap the heat shrink tube on both wires. 6. Use the heat gun to heat the repaired area until adhesive flows out both ends of the heat shrink tube. 7. Reconnect the battery ground cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Tools and Equipment > Tools and Equipment Module Communication Network: Tools and Equipment Special Tool(s) Heat Gun Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Module Communication Network <--> [Information Bus] > Component Information > Tools and Equipment > Tools and Equipment > Page 3598 Module Communication Network: Tools and Equipment Diagnostic Special Service Tool(S) Special Tool(s) Worldwide Diagnostic System (WDS) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations View 151-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3602 Connector View C109 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3603 Knock Sensor: Description and Operation Knock Sensor Knock Sensor (KS) The knock Sensor (KS) (Figure 34) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3604 Knock Sensor: Service and Repair REMOVAL 1. Disconnect the Knock Sensor (KS) electrical connector. 2. Remove the intake manifold. 3. Remove the KS. 1 Remove the bolt. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Powertrain Control Module Power Relay: Locations Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3608 Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3609 Connector View C1016 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3610 Powertrain Control Module Power Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3611 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation Malfunction Indicator Lamp (MIL) Check Engine, Service Engine Soon Or ISO Standard Engine Symbol The Malfunction Indicator Lamp (MIL) (Figure 15) alerts the driver that the Powertrain Control Module (PCM) has detected an On Board Diagnostic (OBD) II emission-related component or system fault. When this occurs, an OBD II Diagnostic Trouble Code (DTC) will be set. - The MIL is located on the instrument cluster and is labeled CHECK ENGINE, SERVICE ENGINE SOON or ISO standard engine symbol (Figure 16). - Power is supplied to the MIL whenever the ignition switch is in the RUN or START position. - The MIL will remain on in the RUN/START mode as a bulb check during the instrument cluster proveout for approximately 4 seconds. - If the MIL remains on after the bulb check: The PCM illuminates the MIL for an emission related concern and a DTC will be present. - The instrument cluster will illuminate the MIL if the PCM does not send a control message to the instrument cluster. - The PCM is operating in the Hardware Limited Operation Strategy (HLOS). - The MIL circuit is shorted to ground. - If the MIL remains off (during the bulb check); Bulb is damaged. - MIL circuit is open. - To turn off the MIL after a repair, a reset command from the Scan Tool must be sent, or three consecutive drive cycles must be completed without a fault. - For any MIL concern, go to Symptom Charts. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Reading Diagnostic Trouble Codes/Performance Diagnostic Procedures/Quick Test - If the MIL blinks at a steady rate, a severe misfire condition could possibly exist. - If the MIL blinks erratically, an intermittent open B+ to the bulb or an intermittent short to ground in the MIL circuit exist. Also, the PCM can reset while cranking if battery voltage is low. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Description and Operation Oil Temperature Sensor For ECM: Description and Operation Engine Oil Temperature Engine Oil Temperature (EOT) Sensor The Engine Oil Temperature (EOT) sensor (Figure 29) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The EOT measures the temperature of the engine oil. The EOT sensor is similar in construction to the engine coolant temperature (ECT) sensor. On some applications, EOT input to the PCM is used to initiate a soft engine shutdown. This prevents engine damage from occurring as a result of high oil temperature. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions Heated Oxygen Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. NOTE: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3623 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number or the component name in one of the the A-Z Component Lists, the Component Location description for that component can easily be found. See: Locations/Component Locations/A-Z Component List Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3624 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3625 the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3626 that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3627 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3628 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3629 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3630 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3631 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3632 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3633 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3634 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3635 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3636 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3637 Systems Overview Wire Color Code Identification Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3638 OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3639 Heated Oxygen Sensor: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3640 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3641 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3642 Heated Oxygen Sensor: Connector Views Connector View C171 Connector View C142 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3643 Connector View C172 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 3644 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > PCM Input Heated Oxygen Sensor: Description and Operation PCM Input Heated Oxygen Sensor Heated Oxygen Sensor (HO2S) The Heated Oxygen Sensor (HO2S) (Figure 32) detects the presence of oxygen in the exhaust and produces a variable voltage according to the amount of oxygen detected. A high concentration of oxygen (lean air/fuel ratio) in the exhaust produces a low voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a high voltage signal greater than 0.6 volt. The HO2S provides feedback to the PCM indicating air/fuel ratio in order to achieve a near stoichiometric air/fuel ratio of 14.7:1 during closed loop engine operation. The HO2S generates a voltage between 0.0 and 1.1 volts. Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to temperatures of 800°C (1400°F). At approximately 300°C (600°F) the engine can enter closed loop operation. The VPWR circuit supplies voltage to the heater and the PCM will complete the ground when the proper conditions occur. For model year 1998 a new HO2S heater and heater control system are installed on some vehicles. The high power heater reaches closed loop fuel control temperatures. The use of this heater requires that the HO2S heater control be duty cycled, to prevent damage to the heater. The 6 ohm design is not interchangeable with new style 3.3 ohm heater. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > PCM Input > Page 3647 Heated Oxygen Sensor: Description and Operation Upstream Heated and Downstream Heated Oxygen Sensors Upstream Heated and Downstream Heated Oxygen Sensors The HO2S provide the Powertrain Control Module (PCM) with voltage and frequency information related to the oxygen content of the exhaust gas. (Refer to the PCM Inputs for a description of how the HO2S operates.) In addition to providing the PCM with indications of how rich/lean the engine is operating, the upstream HO2S signal serves as an input to the HO2S monitor. The downstream HO2S signal is an input to the Catalyst Efficiency monitor. (Refer to the OBD II Monitors for specific information on these monitors.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Page 3648 Heated Oxygen Sensor: Service and Repair Socket, Exhaust Gas Oxygen Sensor SPECIAL TOOL(S) REMOVAL Left side sensor 1. Raise and support the vehicle. Right side sensor 2. Remove the right front wheel and tire assembly. 3. Position aside the right front fender splash shield. Both sensors 4. Using the special tool, remove the HO2S. NOTE: If necessary, lubricate the HO2S with lock lubricant to assist in removal. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Apply a light coat of anti-seize lubricant to the threads of the HO2S. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Page 3649 Socket, Exhaust Gas Oxygen Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Signal > Component Information > Description and Operation Power Steering Pressure Signal: Description and Operation Power Steering Pressure Sensor Power Steering Pressure (PSP) Sensor The power steering pressure (PSP) sensor (Figure 38) monitors the hydraulic pressure within the power steering system. The PSP sensor voltage input to the PCM will change as the hydraulic pressure changes. The PCM uses the input signal from the PSP sensor to compensate for additional loads on the engine by adjusting the idle rpm and preventing engine stall during parking maneuvers. Also, the PSP sensor signals the PCM to adjust transmission electronic pressure control (EPC) pressure during the increased engine load, for example during parking maneuvers. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3661 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3662 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3663 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3664 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3665 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3671 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3672 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3673 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3674 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3675 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3680 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3681 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3682 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3688 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3689 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3690 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3691 View 151-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3692 Connector View C1068 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3693 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR Sensor Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 86) is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Tube Mounted Differential Pressure Feedback EGR Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3694 Tube Mounted Differential Pressure Feedback EGR Sensor The tube mounted differential pressure feedback EGR sensor (Figure 87) is identical in operation as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the underside of the sensor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3695 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the differential pressure feedback Exhaust Gas Recirculation (EGR). 1 Disconnect the electrical connector. 2 Disconnect the hoses. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3705 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3706 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3707 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls General PCM Programming Procedures Powertrain Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls General PCM Programming Procedures > Page 3713 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls General PCM Programming Procedures > Page 3714 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls DTC P1635 Set After PCM/IC Replacement > Page 3719 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls DTC P1635 Set After PCM/IC Replacement > Page 3720 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls DTC P1635 Set After PCM/IC Replacement > Page 3721 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls General PCM Programming Procedures Powertrain Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls General PCM Programming Procedures > Page 3727 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls General PCM Programming Procedures > Page 3728 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3729 View 151-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3730 Powertrain Control Module: Diagrams Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3731 Part 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3732 Powertrain Control Module: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the Powertrain Control Module (PCM) electrical connector. 3. Remove the nuts and the PCM cover. 4. Remove the PCM. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Powertrain Control Module Power Relay: Locations Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3736 Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3737 Connector View C1016 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3738 Powertrain Control Module Power Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3739 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Description and Operation Absolute Pressure Sensor: Description and Operation Thermal Manifold Absolute Pressure Sensor Thermal Manifold Absolute Pressure (TMAP) Sensor The Thermal Manifold Absolute Pressure Sensor (TMAP) (Figure 40) consists of a Manifold Absolute Pressure (MAP) sensor and an integrated thermistor. The thermistor part of the sensor is currently not being used. The MAP part of the sensor measures intake manifold air absolute pressure. The PCM uses information from the MAP sensor, Throttle Position (TP) sensor, mass air flow (MAF) sensor, engine coolant temperature (ECT) or cylinder head temperature (CHT) sensor and crankshaft position (CKP) sensor to determine how much exhaust gas is introduced into the intake manifold. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations View 151-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3747 Connector View C128 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3748 Mass Air Flow Sensor: Service Precautions CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3749 Mass Air Flow Sensor: Description and Operation Mass Air Flow Sensor Typical Mass Air Flow (MAF) Sensor Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire Terminals The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 35). If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio (Figure 36). This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3750 Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated intake air temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar, Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3751 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Loosen the air cleaner outlet tube clamp and position the tube aside. 3. Remove the four bolts and the MAF sensor. CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations View 151-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3755 Connector View C180 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > PCM Input Camshaft Position Sensor: Description and Operation PCM Input Camshaft Position Sensor The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No.1 is on its compression stroke. A signal is then sent to the powertrain control module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctance Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22) and the two pin connector variable reluctance sensor (Figure 23). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > PCM Input > Page 3758 Camshaft Position Sensor: Description and Operation Ignition Systems Camshaft Position Sensor Camshaft Position (CMP) Sensor The camshaft position sensor (Figure 55) used by COP Integrated EI system is a magnetic transducer mounted on the engine front cover adjacent to the camshaft. By monitoring a target on the camshaft sprocket, the CMP sensor identifies cylinder one to the PCM. The COP Integrated EI system uses this information to synchronize the firing of the individual coils. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 3759 Camshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams Connector View C257 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams > Page 3763 Clutch Switch: Description and Operation Clutch Pedal Position Switch Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch (Figure 24) is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations View 151-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Engine Coolant Temperature (ECT) Sender Connector View C1061 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Engine Coolant Temperature (ECT) Sender > Page 3769 Connector View C1064 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 3770 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Engine Coolant Temperature (ECT) Sensor The Engine Coolant Temperature (ECT) sensor (Figure 27) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. The ECT sensor is similar in construction to the IAT sensor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 3771 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector. 2. Remove the retaining clip and the ECT sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations View 151-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3775 Connector View C101 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > PCM Input Crankshaft Position Sensor: Description and Operation PCM Input Crankshaft Position Sensor (Integrated Ignition Systems) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the powertrain control module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to fixed reference (Figure 25). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > PCM Input > Page 3778 Crankshaft Position Sensor: Description and Operation Ignition Systems Crankshaft Position Sensor Typical Crankshaft Position (CKP) Sensor The crankshaft position (CKP) sensor (Figure 54) is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP sensor is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to a fixed reference (Figure 54) for the CKP sensor configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between teeth. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Page 3779 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Crankshaft Position (CKP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ The new CKP sensor needs to be touching the damper. The new sensor has wear tabs that will wear off after several engine revolutions. ^ Be sure the sensor wiring is routed away from the battery cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor Cylinder Head Temperature (CHT) Sensor The Cylinder Head Temperature (CHT) sensor (Figure 26) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The cylinder head temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. For additional information, refer to Powertrain Control Software for Fail-Safe Cooling Strategy details. See: Description and Operation/Powertrain Control Software Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions Fuel Tank Pressure Sensor: Service Precautions CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions > Page 3786 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure Sensor Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The Fuel Tank Pressure (FTP) sensor (Figure 97) or inline fuel tank pressure (FTP) sensor (Figure 98) is used to measure the fuel tank pressure during the EVAP monitor test on vehicles equipped with the Running Loss-type system. Also, it is used to control excessive fuel tank pressure by forcing the system to purge. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service Precautions > Page 3787 Fuel Tank Pressure Sensor: Service and Repair REMOVAL 1. Remove the fuel tank. 2. Remove the fuel tank pressure sensor. 1 Disconnect the electrical connector. 2 Press down and rotate the fuel tank pressure sensor counterclockwise and remove it from the fuel tank. CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. INSTALLATION 1. To install, reverse removal procedure. ^ Leak test. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Evaporative Emission System Leak Test ^ Carry out the evaporative emissions repair verification drive cycle. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Evaporative Emission Repair Verification Drive Cycle Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Description and Operation Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor Intake Air Temperature (IAT) The Intake Air Temperature (IAT) sensors (Figure 33) and integrated Mass Air Flow (MAF) type (Figure 36), are thermistor devices in which resistance changes with temperature The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of fuel, spark and MAF. The IAT sensor provides a quicker temperature change response time than the ECT or CHT sensor. Supercharged vehicles use (2) IAT sensors. Both sensors are thermistor type devices and operate as above. However, one is located before the supercharger at the air cleaner for standard OBD II/cold weather input, while a second sensor (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control border-line spark and to help determine intercooler efficiency. Currently two types of IAT2 sensors are used. A screw in type (Figure 33) and an integrated type, witch is part of the Thermal Manifold Absolute Pressure (TMAP) sensor (Figure 40). The TMAP sensor consists of a IAT thermistor and a Manifold Absolute Pressure (MAP) sensor. The thermistor portion of the TMAP is used for IAT2 function and operates in the same manner as a non-integrated IAT2. For additional information on the MAP portion of the TMAP, refer to the Thermal Manifold Absolute Pressure Sensor description and operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations View 151-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3794 Connector View C109 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3795 Knock Sensor: Description and Operation Knock Sensor Knock Sensor (KS) The knock Sensor (KS) (Figure 34) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3796 Knock Sensor: Service and Repair REMOVAL 1. Disconnect the Knock Sensor (KS) electrical connector. 2. Remove the intake manifold. 3. Remove the KS. 1 Remove the bolt. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Description and Operation Oil Temperature Sensor For ECM: Description and Operation Engine Oil Temperature Engine Oil Temperature (EOT) Sensor The Engine Oil Temperature (EOT) sensor (Figure 29) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The EOT measures the temperature of the engine oil. The EOT sensor is similar in construction to the engine coolant temperature (ECT) sensor. On some applications, EOT input to the PCM is used to initiate a soft engine shutdown. This prevents engine damage from occurring as a result of high oil temperature. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions Heated Oxygen Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. NOTE: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3805 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number or the component name in one of the the A-Z Component Lists, the Component Location description for that component can easily be found. See: Locations/Component Locations/A-Z Component List Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3806 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3807 the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3808 that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3809 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3810 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3811 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3812 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3813 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3814 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3815 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3816 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3817 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3818 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3819 Systems Overview Wire Color Code Identification Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3820 OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3821 Heated Oxygen Sensor: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3822 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3823 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3824 Heated Oxygen Sensor: Connector Views Connector View C171 Connector View C142 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3825 Connector View C172 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 3826 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > PCM Input Heated Oxygen Sensor: Description and Operation PCM Input Heated Oxygen Sensor Heated Oxygen Sensor (HO2S) The Heated Oxygen Sensor (HO2S) (Figure 32) detects the presence of oxygen in the exhaust and produces a variable voltage according to the amount of oxygen detected. A high concentration of oxygen (lean air/fuel ratio) in the exhaust produces a low voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a high voltage signal greater than 0.6 volt. The HO2S provides feedback to the PCM indicating air/fuel ratio in order to achieve a near stoichiometric air/fuel ratio of 14.7:1 during closed loop engine operation. The HO2S generates a voltage between 0.0 and 1.1 volts. Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to temperatures of 800°C (1400°F). At approximately 300°C (600°F) the engine can enter closed loop operation. The VPWR circuit supplies voltage to the heater and the PCM will complete the ground when the proper conditions occur. For model year 1998 a new HO2S heater and heater control system are installed on some vehicles. The high power heater reaches closed loop fuel control temperatures. The use of this heater requires that the HO2S heater control be duty cycled, to prevent damage to the heater. The 6 ohm design is not interchangeable with new style 3.3 ohm heater. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > PCM Input > Page 3829 Heated Oxygen Sensor: Description and Operation Upstream Heated and Downstream Heated Oxygen Sensors Upstream Heated and Downstream Heated Oxygen Sensors The HO2S provide the Powertrain Control Module (PCM) with voltage and frequency information related to the oxygen content of the exhaust gas. (Refer to the PCM Inputs for a description of how the HO2S operates.) In addition to providing the PCM with indications of how rich/lean the engine is operating, the upstream HO2S signal serves as an input to the HO2S monitor. The downstream HO2S signal is an input to the Catalyst Efficiency monitor. (Refer to the OBD II Monitors for specific information on these monitors.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Page 3830 Heated Oxygen Sensor: Service and Repair Socket, Exhaust Gas Oxygen Sensor SPECIAL TOOL(S) REMOVAL Left side sensor 1. Raise and support the vehicle. Right side sensor 2. Remove the right front wheel and tire assembly. 3. Position aside the right front fender splash shield. Both sensors 4. Using the special tool, remove the HO2S. NOTE: If necessary, lubricate the HO2S with lock lubricant to assist in removal. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Apply a light coat of anti-seize lubricant to the threads of the HO2S. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Page 3831 Socket, Exhaust Gas Oxygen Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3840 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3841 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3842 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3843 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3844 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3850 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3851 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3852 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3853 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3854 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3859 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3860 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3861 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 3867 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 3868 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 3869 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3870 View 151-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3871 Connector View C1068 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3872 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR Sensor Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 86) is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Tube Mounted Differential Pressure Feedback EGR Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3873 Tube Mounted Differential Pressure Feedback EGR Sensor The tube mounted differential pressure feedback EGR sensor (Figure 87) is identical in operation as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the underside of the sensor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3874 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the differential pressure feedback Exhaust Gas Recirculation (EGR). 1 Disconnect the electrical connector. 2 Disconnect the hoses. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations View 151-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3878 Connector View C189 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3879 Throttle Position Sensor: Description and Operation Throttle Position Sensor Typical Throttle Position (TP) Sensor The throttle position (TP) sensor (Figure 41) is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is monitored by the OBD II system for component integrity, system functionality, and faults that can cause emissions levels to exceed standards set in government regulations. For additional information on the TP sensor, refer to Electronic EC System Hardware-PCM Inputs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3880 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove the accelerator control snow shield. 2. Remove the Throttle Position (TP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolts and the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission Range (TR) sensor screws .......................................................................................................................... 8-11 Nm (71-97 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3884 View 151-5 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3885 Connector View C167 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3886 Digital Transmission Range Sensor: Description and Operation Digital Transmission Range (TR) Sensor The digital Transmission Range (TR) sensor is located on the outside of the transmission at the manual lever. The digital TR sensor completes the start circuit in PARK, NEUTRAL, and the back-up lamp circuit in REVERSE. The digital TR sensor also opens and closes a set of four switches that are monitored by the Powertrain Control Module (PCM) to determine the position of the manual lever (P, R, N, (D), 3, 2, 1). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3887 Digital Transmission Range Sensor: Service and Repair Digital Transmission Range (TR) Sensor Special Tools Special Tool(s) Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Disconnect the shift cable from the manual control lever. 4. Disconnect the digital Transmission Range (TR) sensor electrical connector. 5. Remove the manual control outer lever nut and manual control outer lever. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3888 6. Remove the screws and the digital TR sensor. Installation 1. Install the digital TR sensor and loosely install the screws. 2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence. 3. Install the manual control outer lever and nut. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3889 4. Connect the digital Transmission Range (TR) sensor electrical connector. 5. Connect the shift cable to the manual control lever. 6. Verify that the shift cable is adjusted. 7. Lower the vehicle. 8. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > PCM Input Vehicle Speed Sensor: Description and Operation PCM Input Vehicle Speed Sensor Typical Vehicle Speed Sensor (VSS) The Vehicle Speed Sensor (VSS) (Figure 44) is a variable reluctance or Hall-effect sensor that generates a waveform with a frequency that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the VSS (and other inputs) to control such parameters as fuel injection, ignition control, transmission/transaxle shift scheduling and torque converter clutch scheduling. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > PCM Input > Page 3894 Vehicle Speed Sensor: Description and Operation PCM Output Powertrain Control Module - Vehicle Speed Output (VSO) The PCM-VSO (Powertrain Control Module - Vehicle Speed Output) speed signal subsystem generates vehicle speed information for distribution to the vehicle's electrical/electronic modules and subsystems that require vehicle speed data. This subsystem senses the transmission output shaft speed with a sensor. The data is processed by the PCM, and distributed as a hard-wired signal or as a multiplexed data message. The key features of the PCM-VSO system are to: ^ Infer vehicle movement from the output shaft sensor signal ^ Convert transmission output shaft rotational information to vehicle speed information ^ Compensate for tire size and axle ratio with a programmed calibration variable ^ Utilize a transfer case sensor for four wheel drive applications ^ Distribute vehicle speed information as a multiplexed message and/or an analog signal The signal from a non-contact shaft sensor (Output Shaft Sensor--OSS or Transfer Case Shaft Sensor--TCSS) mounted on the transmission (automatics, manuals, or 4X4 transfer cases) is sensed directly by the PCM. The PCM converts the OSS or TCSS information to 8000 pulses per mile, based on a tire and axle ratio conversion factor. This conversion factor is programmed into the PCM at the time the vehicle is assembled and can be reprogrammed in the field for servicing changes in the tire size and axle ratio. The PCM transmits the computed vehicle speed and distance traveled information to all the vehicle speed signal users on the vehicle. VSO information can be transmitted by a hard-wired interface between the vehicle speed signal user and the PCM, or by Speed and Odometer SCP multiplexed data messages. The VSO hard-wired signal wave form is a DC square wave with a voltage level of 0 to VBAT. Typical output operating range is 2.22Hz per MPH ( 1.3808 Hz pr 1 Km/h). Multiplexed data for speed and distance data are transmitted as separate SCP messages over the SCP multiplex link. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations View 151-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3898 Connector View C189 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3899 Throttle Position Sensor: Description and Operation Throttle Position Sensor Typical Throttle Position (TP) Sensor The throttle position (TP) sensor (Figure 41) is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is monitored by the OBD II system for component integrity, system functionality, and faults that can cause emissions levels to exceed standards set in government regulations. For additional information on the TP sensor, refer to Electronic EC System Hardware-PCM Inputs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3900 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove the accelerator control snow shield. 2. Remove the Throttle Position (TP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolts and the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission Range (TR) sensor screws .......................................................................................................................... 8-11 Nm (71-97 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3904 View 151-5 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3905 Connector View C167 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3906 Digital Transmission Range Sensor: Description and Operation Digital Transmission Range (TR) Sensor The digital Transmission Range (TR) sensor is located on the outside of the transmission at the manual lever. The digital TR sensor completes the start circuit in PARK, NEUTRAL, and the back-up lamp circuit in REVERSE. The digital TR sensor also opens and closes a set of four switches that are monitored by the Powertrain Control Module (PCM) to determine the position of the manual lever (P, R, N, (D), 3, 2, 1). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3907 Digital Transmission Range Sensor: Service and Repair Digital Transmission Range (TR) Sensor Special Tools Special Tool(s) Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Disconnect the shift cable from the manual control lever. 4. Disconnect the digital Transmission Range (TR) sensor electrical connector. 5. Remove the manual control outer lever nut and manual control outer lever. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3908 6. Remove the screws and the digital TR sensor. Installation 1. Install the digital TR sensor and loosely install the screws. 2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence. 3. Install the manual control outer lever and nut. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3909 4. Connect the digital Transmission Range (TR) sensor electrical connector. 5. Connect the shift cable to the manual control lever. 6. Verify that the shift cable is adjusted. 7. Lower the vehicle. 8. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System Variable Valve Timing Actuator: Description and Operation Variable Cam Timing System Overview The Variable Cam Timing System allows the exhaust cam to advance and retard at varying engine speeds. The purpose of this is to reduce exhaust emissions and increase fuel economy. As the exhaust cam retards in relation to the crankshaft position, residual exhaust gases are left in the combustion chamber. The residual gases cool the combustion chamber and are inert when mixed with the incoming fresh charge of fuel and air. This results in better fuel economy and lower Nitrogen Oxides (NOx) and Hydrocarbons (HC) the engine produces. The Exhaust Gas Recalculation System (EGR) is unnecessary on the 2.0L (4V) engine due to this feature. Variable Cam Timing Variable Cam Timing System The Variable Cam Timing (VCT) System consists of the control solenoid, five-tooth pulse ring (4+1) on exhaust camshaft, Intake Air Temperature (IAT) sensor, Engine Coolant Temperature (ECT) sensor, Camshaft Position (CMP) sensor, Mass Air Flow (MAF) sensor, Crankshaft Position (CKP) sensor, Powertrain Control Module (PCM) (Figure 127). 1. The powertrain control module (PCM) receives input signals from the intake air temperature (IAT) sensor, engine coolant temperature (ECT) sensor, camshaft position (CMP) sensor, mass air flow (MAF) sensor and crankshaft position (CKP) sensor for determining the operating conditions of the engine. 2. The Variable Cam Timing (VCT) system is enabled by the PCM when the proper conditions are met. The PCM disables the VCT system if a fault is detected. 3. The PCM calculates relative cam position using the CMP sensor and data from the (4+1) pulse ring mounted on the exhaust camshaft. Relative cam position is calculated by measuring the time between the rising edge of Profile Ignition Pickup (PIP) and the falling edge of VCT pulse. 4. The PCM continually calculates a cam position error value based on the difference between the desired and actual position and a duty cycle is commanded for the VCT solenoid valve. Engine oil is allowed to flow to the VCT unit. 5. Oil flows to either side of the piston chamber changing a linear motion from the piston to a rotation motion from the helical mechanism in the VCT unit. During closed loop the PCM outputs a revised duty cycle to the VCT solenoid valve to correct for cam position error. Hardware Variable Cam Timing (VCT) Solenoid Valve Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System > Page 3914 Variable Cam Timing (VCT) Solenoid Valve The VCT solenoid valve (Figure 128) is an integral part of the VCT system. The solenoid valve controls the flow of engine oil to the variable cam timing unit assembly. As the PCM duty cycles the solenoid valve, oil is allowed to flow to the VCT unit assembly and advance or retard the cam timing. Variable Cam Timing (VCT) Unit Assembly Variable Cam Timing Unit Assembly The variable cam timing unit assembly (Figure 129) is coupled to the camshaft through a helical spline in the VCT unit chamber. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the piston to move linearly along the axis of the camshaft. This linear motion is translated into rotational camshaft motion through the helical spline coupling. A spring installed in the chamber is designed to hold the camshaft in the minimum overlap position (5 degrees) when oil pressure is too low to maintain adequate position control. The camshaft is allowed to rotate up to 30 degrees. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System > Page 3915 Variable Valve Timing Actuator: Description and Operation Variable Cam Timing (VCT) Unit Assembly Variable Cam Timing (VCT) Unit Assembly Variable Cam Timing Unit Assembly The variable cam timing unit assembly (Figure 129) is coupled to the camshaft through a helical spline in the VCT unit chamber. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the piston to move linearly along the axis of the camshaft. This linear motion is translated into rotational camshaft motion through the helical spline coupling. A spring installed in the chamber is designed to hold the camshaft in the minimum overlap position (5 degrees) when oil pressure is too low to maintain adequate position control. The camshaft is allowed to rotate up to 30 degrees. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Description and Operation Variable Valve Timing Solenoid: Description and Operation Variable Cam Timing (VCT) Solenoid Valve Variable Cam Timing (VCT) Solenoid Valve The VCT solenoid valve (Figure 128) is an integral part of the VCT system. The solenoid valve controls the flow of engine oil to the variable cam timing unit assembly. As the PCM duty cycles the solenoid valve, oil is allowed to flow to the VCT unit assembly and advance or retard the cam timing. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > PCM Input Vehicle Speed Sensor: Description and Operation PCM Input Vehicle Speed Sensor Typical Vehicle Speed Sensor (VSS) The Vehicle Speed Sensor (VSS) (Figure 44) is a variable reluctance or Hall-effect sensor that generates a waveform with a frequency that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the VSS (and other inputs) to control such parameters as fuel injection, ignition control, transmission/transaxle shift scheduling and torque converter clutch scheduling. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > PCM Input > Page 3923 Vehicle Speed Sensor: Description and Operation PCM Output Powertrain Control Module - Vehicle Speed Output (VSO) The PCM-VSO (Powertrain Control Module - Vehicle Speed Output) speed signal subsystem generates vehicle speed information for distribution to the vehicle's electrical/electronic modules and subsystems that require vehicle speed data. This subsystem senses the transmission output shaft speed with a sensor. The data is processed by the PCM, and distributed as a hard-wired signal or as a multiplexed data message. The key features of the PCM-VSO system are to: ^ Infer vehicle movement from the output shaft sensor signal ^ Convert transmission output shaft rotational information to vehicle speed information ^ Compensate for tire size and axle ratio with a programmed calibration variable ^ Utilize a transfer case sensor for four wheel drive applications ^ Distribute vehicle speed information as a multiplexed message and/or an analog signal The signal from a non-contact shaft sensor (Output Shaft Sensor--OSS or Transfer Case Shaft Sensor--TCSS) mounted on the transmission (automatics, manuals, or 4X4 transfer cases) is sensed directly by the PCM. The PCM converts the OSS or TCSS information to 8000 pulses per mile, based on a tire and axle ratio conversion factor. This conversion factor is programmed into the PCM at the time the vehicle is assembled and can be reprogrammed in the field for servicing changes in the tire size and axle ratio. The PCM transmits the computed vehicle speed and distance traveled information to all the vehicle speed signal users on the vehicle. VSO information can be transmitted by a hard-wired interface between the vehicle speed signal user and the PCM, or by Speed and Odometer SCP multiplexed data messages. The VSO hard-wired signal wave form is a DC square wave with a voltage level of 0 to VBAT. Typical output operating range is 2.22Hz per MPH ( 1.3808 Hz pr 1 Km/h). Multiplexed data for speed and distance data are transmitted as separate SCP messages over the SCP multiplex link. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Solenoid > Component Information > Description and Operation Air Diverter Solenoid: Description and Operation AIR Bypass Solenoid Secondary Air Injection Bypass Solenoid The secondary Air Injection Bypass (AIR bypass) solenoid (Figure 122) is used by the PCM to control vacuum to the secondary air injection diverter (AIR diverter) valve. The AIR bypass solenoid is a normally closed solenoid. The AIR bypass solenoid also has a filtered vent feature to permit vacuum release. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Valve > Component Information > Description and Operation Air Diverter Valve: Description and Operation AIR Diverter Valve Air Injection Diverter (AIR Diverter) Valve The secondary Air Injection Diverter (AIR diverter) valve (Figure 123) is used with the electric AIR pump to provide on/off control of air to the exhaust manifold and catalytic converter. When the electric AIR pump is on and vacuum is supplied to the AIR diverter valve, air passes the integral check valve disk. When the electric AIR pump is off, and vacuum is removed from the AIR diverter valve, the integral check valve disk is held on the seat and stops air from being drawn into the exhaust system and prevents the back flow of the exhaust into the Secondary Air Injection System. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump > Component Information > Description and Operation Air Injection Pump: Description and Operation Electric AIR Pump Electric Air Pump The electric AIR pump (Figure 121) provides pressurized air to the Secondary Air Injection system. The electric AIR pump functions independently of rpm and is controlled by the PCM. The electric AIR pump is only used for short periods of time. Delivery of air is dependent on the amount of system backpressure and system voltage. The inlet system of the AIR pump incorporates a non-serviceable filter and splash cap which helps to guard against dirt and water. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump Relay > Component Information > Description and Operation Air Injection Pump Relay: Description and Operation Solid State Relay Solid State Relay The solid state relay (Figure 124) switches the high current required for operation of the electric AIR pump. Input control to the solid state relay comes from the powertrain control module (PCM). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Vacuum Check Valve, AIR > Component Information > Description and Operation Vacuum Check Valve: Description and Operation Vacuum Check Valves Vacuum Check Valve A vacuum check valve (Figure 125) blocks air flow in one direction. It allows free air flow in the other direction. The check side of this valve will hold the highest vacuum registered on the vacuum side. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Customer Interest for Catalytic Converter: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur Smell Technical Service Bulletin # 02-21-6 Date: 021028 Engine Controls/Emissions - Exhaust Sulfur Smell Article No. 02-21-6 10/28/02 ^ DRIVEABILITY - EXCESSIVE SULFUR SMELL FROM EXHAUST ^ EXHAUST - EXCESSIVE SULFUR SMELL FROM EXHAUST FORD: 2001-2002 EXPLORER SPORT 2002 EXPLORER SPORT TRAC 2002-2003 EXPLORER MERCURY: 2002-2003 MOUNTAINEER Article 02-16-6 is being republished in its entirety to update the Service Procedure and model years. ISSUE Some vehicles may exhibit excessive sulfur smell from the exhaust under certain drive modes. This may be due to the highly active state of a new catalyst, calibration factors, underbody catalyst temperature, and amount of sulfur present in the fuel. ACTION Identify year, model, and build date to identify appropriate service procedure. For applications that require installing exhaust wrap, use good quality stainless steel worm-drive hose clamps for best longevity, similar to what would commonly be used for exhaust heat shield rattle issues. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 02-16-6 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 022106A Install Exhaust Wrap And 1.4 Hrs. Perform Drive Sequence. 2002-2003 Explorer/Mountaineer 4.0L Vehicles Built 1-14-02 Through 12-02-02, 4.6L Built Prior To 12-02-02 022106B Install Exhaust Wrap, 1.6 Hrs. Reprogram Powertrain Control Module And Perform Drive Sequence. 2002-2003 Explorer/Mountaineer 4.0L Built Prior To 1-14-02 022106C Replace Catalytic 0.8 Hr. Converter And Reprogram Powertrain Control Module. 2001-2002 Explorer Sport Vehicles Built 7-24-00 Through 3-4-02, 2002 Sport Trac 11-02-01 Through 3-4-02 022106D Replace Catalytic 0.6 Hr. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Customer Interest for Catalytic Converter: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur Smell > Page 3949 Converter Only. 2002 Explorer Sport/Sport Trac 3-4-02 Through 3-27-02 With Automatic Transmission, 11-02-01 Through 3-4-02 With Manual Transmission DEALER CODING CONDITION BASIC PART NO. CODE 5F250 42 OASIS CODES: 403000, 499000 Disclaimer Service Procedure 2002-2003 4 DOOR EXPLORER/MOUNTAINEER 4.0L Vehicles Built 1/14/02 Through 12/02/2002 At latest level for engine calibration. 1. Install Exhaust wrap on the pipes between the light-off and the underbody catalyst referring to the instruction sheet in the kit. 2. Refer to Drive Sequence heading to purge stored sulfur from catalyst. 3. See Contributing Factors heading for additional information. NOTE CONVERTER REPLACEMENT OR RECALIBRATION IS NOT NECESSARY. Vehicles Built Before 1/14/02 1. Verify that WDS is at the latest level, B21.0 or higher. 2. Reprogram the PCM with the latest calibration. 3. Install Exhaust wrap on the pipes between the light-off and the underbody catalyst referring to the instruction sheet in the kit. 4. Refer to Drive Sequence heading to purge stored sulfur from catalyst. 5. See Contributing Factors Heading for additional information. NOTE DO NOT REPLACE THE CONVERTER. 2002-2003 4 DOOR EXPLORER/MOUNTAINEER 4.6L Vehicles Built Prior To 12/02/2002 1. Install Exhaust wrap on the pipes between the light-off and the underbody catalyst referring to the instruction sheet in the kit. 2. Refer to Drive Sequence heading to purge stored sulfur from catalyst. 3. See Contributing Factors Heading for additional information. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Customer Interest for Catalytic Converter: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur Smell > Page 3950 NOTE CONVERTER REPLACEMENT OR RECALIBRATION IS NOT NECESSARY. 2001-2002 2 DOOR EXPLORER SPORT 4.0L 7/24/00 Through 3/4/02 With 5R55E Transmission 1. Refer to 2001/2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the old catalytic converter and install the revised converter 2L2Z-5E212-DA. 2. Verify that WDS is at the latest level, B21.0 or higher. 3. Reprogram the PCM with the latest calibration only. 4. See Contributing Factors Heading for additional information. NOTE DO NOT REPLACE CONVERTER MORE THAN ONCE. 2002 2 DOOR EXPLORER SPORT/SPORT TRAC 4.0L Vehicles Built After 3/27/02 At latest level for engine calibration and converter, no service action will improve the situation. 1. See Contributing Factors Heading for additional information. 3/4/02 Through 3/27/02 1. Refer to 2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the old catalytic converter and install the revised converter 2L2Z-5E212-AB only. 2. See Contributing Factors Heading for additional information. NOTE DO NOT REPLACE CONVERTER MORE THAN ONCE OR RECALIBRATE. 2002 2 DOOR EXPLORER SPORT/SPORT TRAC 4.0L M5R4 MANUAL TRANSMISSION 11/2/01 Through 3/4/02 With Manual Transmission 1. Refer to 2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the old catalytic converter and install the revised converter 2L2Z-5E212-DA only. 2. See Contributing Factors Heading for additional information. NOTE DO NOT REPLACE CONVERTER MORE THAN ONCE OR RECALIBRATE. 2002 SPORT TRAC 4.0L 5R55E TRANSMISSION 11/2/01 Through 3/4/02 With 5R55E Transmission 1. Refer to 2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the old catalytic converter and install the revised converter 2L2Z-5E212-DA. 2. Verify that WDS is at the latest level, B21.0 or higher. 3. Reprogram the PCM with the latest calibration. 4. See Contributing Factors Heading for additional information. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Customer Interest for Catalytic Converter: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur Smell > Page 3951 NOTE DO NOT REPLACE CONVERTER MORE THAN ONCE. DRIVE SEQUENCE AFTER REPAIRS COMPLETED Check engine oil and coolant levels. Verify both are at specified levels before driving vehicle. Perform highway driving at normal highway speeds for 30 miles. The optimum engine speed for this drive sequence is 3,000 to 4,500 rpm, and this can be accomplished by manually selecting the transmission gear state. The goal of the drive procedure is to maintain a constant high temperature level in the exhaust system through the use of increased engine speed. The combination of increased temperature and driving will provide a sulfur cleaning environment for the catalyst system. CONTRIBUTING FACTORS TO SULFUR SMELL Factors outside of engineering control may lead to a sulfur odor. A large contributing factor is the amount of sulfur in the fuel. Replacing a Catalytic Converter multiple times will not alleviate the sulfur odor. Several catalyst replacements on the same vehicle may actually increase customer sensitivity to an exhaust odor concern. Based on some driving habits the converter does not get hot enough to burn out stored sulfur residue and can produce a sulfur odor. For example: ^ Extended Idle - Increase sulfur odor ^ Stop and go driving - Increase sulfur odor ^ Trailer Towing - Decrease sulfur odor ^ Heavy Loads - Decrease sulfur odor Short trips - Increase sulfur odor ^ Abrupt accel/decel - Decrease sulfur odor ^ Hotter driving conditions - Decrease sulfur odor ^ Hilly terrain - Decrease sulfur odor ^ Canceling Overdrive - Decrease sulfur odor Catalysts with 5,000-10,000 Miles (8,000-16,000 kilometers) are likely to have a sulfur smell due to the highly active state of the new catalyst. Refer to symptom chart # 22 of PCED for appropriate year. Additives in fuels (Ethanol, Methanol, ETC.) can cause sulfur odor, suggest using a different fuel source. Geographic variations on sulfur odor intensity are possible due to different refineries supplying fuel to different areas of the country. California regulated fuel will exhibit less sulfur odor. Experiment with different fuel brands. Some contain more sulfur than others, which can lead to an increase in sulfur odor from the converter. Sulfur odors are an aromatic phenomenon and do not cause any durability or safety concerns with vehicle operation. To summarize for the customer, explain that sulfur is in the fuel used and the catalyst system on their vehicle as a result of the fuel and driving environment which creates a condition where sulfur has been stored in their exhaust system. The service action performed allows the sulfur to pass through the exhaust system and to clean the existing sulfur deposits. During the initial cleansing of the catalyst it is expected that a sulfur odor may still be present, and this odor may change from the "rotten egg smell" to that of a "burning match". The odor will cease with time. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Customer Interest for Catalytic Converter: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur Smell > Page 3952 PCM Calibration Information Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Customer Interest for Catalytic Converter: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur Smell > Page 3953 SUPERSEDES:02-16-6 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 022106A Install Exhaust Wrap And 1.4 Hrs. Perform Drive Sequence. 2002-2003 Explorer/Mountaineer 4.0L Vehicles Built 1-14-02 Through 12-02-02, 4.6L Built Prior To 12-02-02 022106B Install Exhaust Wrap, 1.6 Hrs. Reprogram Powertrain Control Module And Perform Drive Sequence. 2002-2003 Explorer/Mountaineer 4.0L Built Prior To 1-14-02 022106C Replace Catalytic 0.8 Hr. Converter And Reprogram Powertrain Control Module. 2001-2002 Explorer Sport Vehicles Built 7-24-00 Through 3-4-02, 2002 Sport Trac 11-02-01 Through 3-4-02 022106D Replace Catalytic 0.6 Hr. Converter Only. 2002 Explorer Sport/Sport Trac 3-4-02 Through 3-27-02 With Automatic Transmission, 11-02-01 Through 3-4-02 With Manual Transmission DEALER CODING CONDITION BASIC PART NO. CODE 5F250 42 OASIS CODES: 403000, 499000 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur Smell Technical Service Bulletin # 02-21-6 Date: 021028 Engine Controls/Emissions - Exhaust Sulfur Smell Article No. 02-21-6 10/28/02 ^ DRIVEABILITY - EXCESSIVE SULFUR SMELL FROM EXHAUST ^ EXHAUST - EXCESSIVE SULFUR SMELL FROM EXHAUST FORD: 2001-2002 EXPLORER SPORT 2002 EXPLORER SPORT TRAC 2002-2003 EXPLORER MERCURY: 2002-2003 MOUNTAINEER Article 02-16-6 is being republished in its entirety to update the Service Procedure and model years. ISSUE Some vehicles may exhibit excessive sulfur smell from the exhaust under certain drive modes. This may be due to the highly active state of a new catalyst, calibration factors, underbody catalyst temperature, and amount of sulfur present in the fuel. ACTION Identify year, model, and build date to identify appropriate service procedure. For applications that require installing exhaust wrap, use good quality stainless steel worm-drive hose clamps for best longevity, similar to what would commonly be used for exhaust heat shield rattle issues. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 02-16-6 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 022106A Install Exhaust Wrap And 1.4 Hrs. Perform Drive Sequence. 2002-2003 Explorer/Mountaineer 4.0L Vehicles Built 1-14-02 Through 12-02-02, 4.6L Built Prior To 12-02-02 022106B Install Exhaust Wrap, 1.6 Hrs. Reprogram Powertrain Control Module And Perform Drive Sequence. 2002-2003 Explorer/Mountaineer 4.0L Built Prior To 1-14-02 022106C Replace Catalytic 0.8 Hr. Converter And Reprogram Powertrain Control Module. 2001-2002 Explorer Sport Vehicles Built 7-24-00 Through 3-4-02, 2002 Sport Trac 11-02-01 Through 3-4-02 022106D Replace Catalytic 0.6 Hr. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur Smell > Page 3959 Converter Only. 2002 Explorer Sport/Sport Trac 3-4-02 Through 3-27-02 With Automatic Transmission, 11-02-01 Through 3-4-02 With Manual Transmission DEALER CODING CONDITION BASIC PART NO. CODE 5F250 42 OASIS CODES: 403000, 499000 Disclaimer Service Procedure 2002-2003 4 DOOR EXPLORER/MOUNTAINEER 4.0L Vehicles Built 1/14/02 Through 12/02/2002 At latest level for engine calibration. 1. Install Exhaust wrap on the pipes between the light-off and the underbody catalyst referring to the instruction sheet in the kit. 2. Refer to Drive Sequence heading to purge stored sulfur from catalyst. 3. See Contributing Factors heading for additional information. NOTE CONVERTER REPLACEMENT OR RECALIBRATION IS NOT NECESSARY. Vehicles Built Before 1/14/02 1. Verify that WDS is at the latest level, B21.0 or higher. 2. Reprogram the PCM with the latest calibration. 3. Install Exhaust wrap on the pipes between the light-off and the underbody catalyst referring to the instruction sheet in the kit. 4. Refer to Drive Sequence heading to purge stored sulfur from catalyst. 5. See Contributing Factors Heading for additional information. NOTE DO NOT REPLACE THE CONVERTER. 2002-2003 4 DOOR EXPLORER/MOUNTAINEER 4.6L Vehicles Built Prior To 12/02/2002 1. Install Exhaust wrap on the pipes between the light-off and the underbody catalyst referring to the instruction sheet in the kit. 2. Refer to Drive Sequence heading to purge stored sulfur from catalyst. 3. See Contributing Factors Heading for additional information. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur Smell > Page 3960 NOTE CONVERTER REPLACEMENT OR RECALIBRATION IS NOT NECESSARY. 2001-2002 2 DOOR EXPLORER SPORT 4.0L 7/24/00 Through 3/4/02 With 5R55E Transmission 1. Refer to 2001/2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the old catalytic converter and install the revised converter 2L2Z-5E212-DA. 2. Verify that WDS is at the latest level, B21.0 or higher. 3. Reprogram the PCM with the latest calibration only. 4. See Contributing Factors Heading for additional information. NOTE DO NOT REPLACE CONVERTER MORE THAN ONCE. 2002 2 DOOR EXPLORER SPORT/SPORT TRAC 4.0L Vehicles Built After 3/27/02 At latest level for engine calibration and converter, no service action will improve the situation. 1. See Contributing Factors Heading for additional information. 3/4/02 Through 3/27/02 1. Refer to 2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the old catalytic converter and install the revised converter 2L2Z-5E212-AB only. 2. See Contributing Factors Heading for additional information. NOTE DO NOT REPLACE CONVERTER MORE THAN ONCE OR RECALIBRATE. 2002 2 DOOR EXPLORER SPORT/SPORT TRAC 4.0L M5R4 MANUAL TRANSMISSION 11/2/01 Through 3/4/02 With Manual Transmission 1. Refer to 2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the old catalytic converter and install the revised converter 2L2Z-5E212-DA only. 2. See Contributing Factors Heading for additional information. NOTE DO NOT REPLACE CONVERTER MORE THAN ONCE OR RECALIBRATE. 2002 SPORT TRAC 4.0L 5R55E TRANSMISSION 11/2/01 Through 3/4/02 With 5R55E Transmission 1. Refer to 2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the old catalytic converter and install the revised converter 2L2Z-5E212-DA. 2. Verify that WDS is at the latest level, B21.0 or higher. 3. Reprogram the PCM with the latest calibration. 4. See Contributing Factors Heading for additional information. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur Smell > Page 3961 NOTE DO NOT REPLACE CONVERTER MORE THAN ONCE. DRIVE SEQUENCE AFTER REPAIRS COMPLETED Check engine oil and coolant levels. Verify both are at specified levels before driving vehicle. Perform highway driving at normal highway speeds for 30 miles. The optimum engine speed for this drive sequence is 3,000 to 4,500 rpm, and this can be accomplished by manually selecting the transmission gear state. The goal of the drive procedure is to maintain a constant high temperature level in the exhaust system through the use of increased engine speed. The combination of increased temperature and driving will provide a sulfur cleaning environment for the catalyst system. CONTRIBUTING FACTORS TO SULFUR SMELL Factors outside of engineering control may lead to a sulfur odor. A large contributing factor is the amount of sulfur in the fuel. Replacing a Catalytic Converter multiple times will not alleviate the sulfur odor. Several catalyst replacements on the same vehicle may actually increase customer sensitivity to an exhaust odor concern. Based on some driving habits the converter does not get hot enough to burn out stored sulfur residue and can produce a sulfur odor. For example: ^ Extended Idle - Increase sulfur odor ^ Stop and go driving - Increase sulfur odor ^ Trailer Towing - Decrease sulfur odor ^ Heavy Loads - Decrease sulfur odor Short trips - Increase sulfur odor ^ Abrupt accel/decel - Decrease sulfur odor ^ Hotter driving conditions - Decrease sulfur odor ^ Hilly terrain - Decrease sulfur odor ^ Canceling Overdrive - Decrease sulfur odor Catalysts with 5,000-10,000 Miles (8,000-16,000 kilometers) are likely to have a sulfur smell due to the highly active state of the new catalyst. Refer to symptom chart # 22 of PCED for appropriate year. Additives in fuels (Ethanol, Methanol, ETC.) can cause sulfur odor, suggest using a different fuel source. Geographic variations on sulfur odor intensity are possible due to different refineries supplying fuel to different areas of the country. California regulated fuel will exhibit less sulfur odor. Experiment with different fuel brands. Some contain more sulfur than others, which can lead to an increase in sulfur odor from the converter. Sulfur odors are an aromatic phenomenon and do not cause any durability or safety concerns with vehicle operation. To summarize for the customer, explain that sulfur is in the fuel used and the catalyst system on their vehicle as a result of the fuel and driving environment which creates a condition where sulfur has been stored in their exhaust system. The service action performed allows the sulfur to pass through the exhaust system and to clean the existing sulfur deposits. During the initial cleansing of the catalyst it is expected that a sulfur odor may still be present, and this odor may change from the "rotten egg smell" to that of a "burning match". The odor will cease with time. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur Smell > Page 3962 PCM Calibration Information Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur Smell > Page 3963 SUPERSEDES:02-16-6 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 022106A Install Exhaust Wrap And 1.4 Hrs. Perform Drive Sequence. 2002-2003 Explorer/Mountaineer 4.0L Vehicles Built 1-14-02 Through 12-02-02, 4.6L Built Prior To 12-02-02 022106B Install Exhaust Wrap, 1.6 Hrs. Reprogram Powertrain Control Module And Perform Drive Sequence. 2002-2003 Explorer/Mountaineer 4.0L Built Prior To 1-14-02 022106C Replace Catalytic 0.8 Hr. Converter And Reprogram Powertrain Control Module. 2001-2002 Explorer Sport Vehicles Built 7-24-00 Through 3-4-02, 2002 Sport Trac 11-02-01 Through 3-4-02 022106D Replace Catalytic 0.6 Hr. Converter Only. 2002 Explorer Sport/Sport Trac 3-4-02 Through 3-27-02 With Automatic Transmission, 11-02-01 Through 3-4-02 With Manual Transmission DEALER CODING CONDITION BASIC PART NO. CODE 5F250 42 OASIS CODES: 403000, 499000 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Catalyst and Exhaust Systems Catalytic Converter: Description and Operation Catalyst and Exhaust Systems Overview Generic Catalyst And Exhaust System The Catalytic Converter and Exhaust Systems (Figure 133) work together to control the release of harmful engine exhaust emissions into the atmosphere. The engine exhaust gas consists mainly of Nitrogen (N), Carbon Dioxide (CO2) and Water Vapor (H2O). However, it also contains Carbon Monoxide (CO), Oxides Of Nitrogen (NOx), Hydrogen (H), and various unburned Hydrocarbons (HCs). CO, NOx, and HCs are major air pollutants, and their emission into the atmosphere must be controlled. The exhaust system generally consists of an exhaust manifold, front exhaust pipe, upstream Heated Oxygen Sensor (HO2S), rear exhaust pipe, downstream HO2S, a muffler and an exhaust tailpipe. The catalytic converter is installed between the front and rear exhaust pipes. Catalytic converter efficiency is monitored by the On Board Diagnostic (OBD II) system. (Refer to OBD II Monitors to Catalyst Efficiency Monitor-Federal Test Procedure for specific information.) Catalytic Converter A catalyst is a material that remains unchanged when it initiates and increases the speed of a chemical reaction. A catalyst will also enable a chemical reaction to occur at a lower temperature. The concentration of exhaust gas products released to the atmosphere must be controlled. The catalytic converter assists in this task. It contains a catalyst in the form of a specially treated ceramic honeycomb structure saturated with catalytically active precious metals. As the exhaust gases come in contact with the catalyst, they are changed into mostly harmless products. The catalyst initiates and speeds up heat producing chemical reactions of the exhaust gas components so they are used up as much as possible. Light Off Catalyst As the catalyst heats up, converter efficiency rises rapidly. The point at which conversion efficiency exceeds 50% is called catalyst light off. For most catalysts this point occurs at 475 to 575°F (246 to 301°C). A fast light catalyst is a Three Way Catalyst (TWC) that is located as close to the exhaust manifold as possible. Because the light off catalyst is located close too the exhaust manifold it will light off faster and reduce emissions quicker than the catalyst located under the body. Once the catalyst lights off, the catalyst will quickly reach the maximum conversion efficiency for that catalyst. TWC Conversion Efficiency Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Catalyst and Exhaust Systems > Page 3966 TWC Conversion Efficiency Chart A TWC requires a stoichiometric fuel ratio, 14.7 pounds of air to 1 pound of fuel (14.7:1), for high conversion efficiency. In order to achieve these high efficiencies, the air/fuel ratio must be tightly controlled with a narrow window of stoichiometry. Devations outside of this window will greatly decrease the conversion efficiency (Figure 134). For example a rich mixture will decrease the HC and CO conversion efficiency while a lean mixture will decreases the NOx conversion efficiency. Exhaust System The purpose of the exhaust system is to convey engine emissions from the exhaust manifold to the atmosphere. Engine exhaust emissions are directed from the engine exhaust manifold to the catalytic converter through the front exhaust pipe. An HO2S is mounted on the front exhaust pipe before the catalyst. The catalytic converter reduces the concentration of carbon monoxide (CO), unburned hydrocarbons (HCs) and oxides of nitrogen (NOx) in the exhaust emissions to an acceptable level. The reduced exhaust emissions are directed from the catalytic converter through another HO2S mounted in the rear exhaust pipe and than on in the muffler. Lastly, the exhaust emissions are directed to the atmosphere through an exhaust tailpipe. Hardware The downstream HO2S may be located after the light off catalyst or underbody catalyst. The underbody catalyst may be in-line with the light off catalyst, or the underbody catalyst may be common to two light off catalysts, forming a "Y" pipe configuration. For an exact configuration of the catalyst and exhaust system, refer to Exhaust System. Three Way Catalytic Converter The three way catalytic (TWC) converter contains either platinum (Pt) and rhodium (Rh) or palladium (Pd) and rhodium (Rh). The TWC converter catalyzes the oxidation reactions of unburned HCs and CO and the reduction reaction of NOx. The three-way conversion can be best accomplished by always operating the engine air fuel/ratio at or close to stoichiometry. Exhaust Manifold/Runners The exhaust manifold runners collect exhaust gases from engine cylinders. The number of exhaust manifolds and exhaust manifold runners depends on the engine configuration and number of cylinders. Exhaust Pipes Exhaust pipes are usually treated during manufacturing with an anti-corrosive coating agent to increase the life of the product. The pipes serve as guides for the flow of exhaust gases from the engine exhaust manifold through the catalytic converter and the muffler. Upstream Heated and Downstream Heated Oxygen Sensors The HO2S provide the Powertrain Control Module (PCM) with voltage and frequency information related to the oxygen content of the exhaust gas. (Refer to the PCM Inputs for a description of how the HO2S operates.) In addition to providing the PCM with indications of how rich/lean the engine is operating, the upstream HO2S signal serves as an input to the HO2S monitor. The downstream HO2S signal is an input to the Catalyst Efficiency monitor. (Refer to the OBD II Monitors for specific information on these monitors.) Muffler Mufflers are usually treated during manufacturing with an anti-corrosive coating agent to increase the life of the product. The muffler reduces the level of noise produced by the engine, and it also reduces the noise produced by exhaust gases as they travel from the catalytic converter to the Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Catalyst and Exhaust Systems > Page 3967 atmosphere. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Catalyst and Exhaust Systems > Page 3968 Catalytic Converter: Description and Operation Catalytic Converter Three Way Catalytic Converter The three way catalytic (TWC) converter contains either platinum (Pt) and rhodium (Rh) or palladium (Pd) and rhodium (Rh). The TWC converter catalyzes the oxidation reactions of unburned HCs and CO and the reduction reaction of NOx. The three-way conversion can be best accomplished by always operating the engine air fuel/ratio at or close to stoichiometry. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 3969 Catalytic Converter: Service and Repair Catalytic Converter-Dual Three-Way Removal and Installation 1. Raise and support the vehicle. 2. Disconnect the catalyst monitor sensor. 3. Remove the bolts and springs. 4. Loosen the LH nuts. 5. Loosen the RH nuts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 3970 6. Remove the nuts. 7. Detach the dual three-way converter from the isolator and remove the converter. 8. Remove the gaskets and, if necessary, the catalyst monitor sensor. ^ Discard the gaskets. 9. CAUTION: Tighten the exhaust component fasteners starting from the rear of the vehicle. NOTE: Make sure to apply anti-seize lubricant to the threads of the sensor prior to installation. To install reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams Connector View C1029 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams > Page 3975 Canister Purge Control Valve: Service Precautions WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams > Page 3976 Canister Purge Control Valve: Description and Operation EVAP Canister Purge Valve EVAP Canister Purge Valve EVAP Canister Purge Valve The EVAP canister purge valve (Figure 95) and (Figure 96) is the part of the Enhanced EVAP system that is controlled by the PCM. This valve controls the flow of vapors (purging) from the EVAP canister to the intake manifold during various engine operating modes. The EVAP canister purge valve is normally closed valve. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams > Page 3977 Canister Purge Control Valve: Service and Repair REMOVAL 1. Remove the battery tray. 2. Disconnect the tubes. 1 Disconnect the electrical connector. 2 Disconnect the tubes from the Evaporative Emission (EVAP) canister purge valve. WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 3. Disconnect the EVAP canister purge valve and bracket. ^ Remove the bolt. 4. Remove the EVAP canister purge valve. 1 Disconnect the vacuum line from the EVAP canister purge valve. 2 Remove the EVAP canister purge valve. INSTALLATION 1. To install, reverse the removal procedure. ^ Leak test the evaporative emissions system. See: Testing and Inspection/Component Tests and General Diagnostics/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. See: Testing and Inspection/Component Tests and General Diagnostics/Evaporative Emission Repair Verification Drive Cycle Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Service Precautions Evaporative Canister Filter: Service Precautions WARNING: ^ THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL ARE PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Service and Repair > Vehicles Built Before 03/2002 Evaporative Canister Filter: Service and Repair Vehicles Built Before 03/2002 REMOVAL 1. Open the liftgate lower and remove the spare tire. 2. Disconnect the battery ground cable. WARNING: THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL ARE PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 3. Disconnect the two chassis emissions lines from the evaporative emission tube. WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 4. Remove the evaporative emissions canister bolts. 5. Remove the evaporative emission canister with bracket assembly. 1 Disconnect the canister vent solenoid electrical connector. 2 Remove the EVAP canister with bracket assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Service and Repair > Vehicles Built Before 03/2002 > Page 3983 6. Disconnect the canister vent solenoid hose assembly. 7. Remove the evaporative emission dust separator. INSTALLATION 1. To install, reverse the removal procedure. ^ Leak test the evaporative emission system. See: Testing and Inspection/Component Tests and General Diagnostics/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. See: Testing and Inspection/Component Tests and General Diagnostics/Evaporative Emission Repair Verification Drive Cycle Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Service and Repair > Vehicles Built Before 03/2002 > Page 3984 Evaporative Canister Filter: Service and Repair Vehicles After Before 03/2002 REMOVAL WARNING: ^ THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, WHICH CAN CAUSE A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUEFIED FUEL ARE PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY. ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND CAN BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY. 1. Remove the evaporative emissions canister. 2. Remove the emissions hose. 3. Remove the dust separator. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Diagrams Connector View C450 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > Recalls: > 03E05 > Jan > 04 > Recall - EVAP Fresh Air Hose Defect Technical Service Bulletin # 03E05 Date: 040101 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > Recalls: > 03E05 > Jan > 04 > Recall - EVAP Fresh Air Hose Defect > Page 3997 Attachment I - Administrative Information Emissions Recall 03E05 Certain 2002 and 2003 MY Explorer Sport Trac Vehicles Evaporative Emissions Canister Fresh Air Inlet Hose Connector Replacement OASIS ACTIVATED? Yes FSA VIN LIST ACTIVATED? Yes NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states provinces and countries. Accordingly you must limit the use of this listing to the follow-up necessary to complete this action. STOCK VEHICLES Correct all affected stock vehicles before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the owner a copy of the Customer Notification Letter and schedule a service date. ^ Also correct other affected vehicles identified in OASIS which are brought to your dealership. RELATED DAMAGE Related damage claims are not approved for this program. ADDITIONAL LABOR TIME Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > Recalls: > 03E05 > Jan > 04 > Recall - EVAP Fresh Air Hose Defect > Page 3998 ^ This repair will require no additional labor time to complete. Claims submitted with "MT" labor will not be accepted for reimbursement. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition call the Special Service Support Center. OWNER REFUNDS ^ Ford Motor Company will only refund owner-paid repairs related to this recall that were made before the date of the Customer Notification Letter (or after the date of the letter if an emergency repair was made away from the servicing dealer). Refund claims that include other non-covered repairs or those judged by Ford to be excessive will not be accepted for reimbursement. ^ This recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close out the VIN for this recall. ^ Refund Claiming Information. (Submit on separate repair line) - Program Code: 03E05 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hr. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION The Evaporative Emissions Fresh Air Inlet Hose Elbow Assembly (9S327) will not be direct shipped for this recall. Order this part through the normal order processing channels. ADDITIONAL PARTS REQUIREMENTS / ORDERING INFORMATION NOTE: This only applies to vehicles that arrive at the dealership with the fresh air inlet hose disconnected. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > Recalls: > 03E05 > Jan > 04 > Recall - EVAP Fresh Air Hose Defect > Page 3999 Dealers must call the Special Service Support Center prior to the repair, if replacement of the EVAP canister assembly is required. Inform the representative you are calling in regard to Emissions Recall 03E05. Be prepared to provide the information shown. ^ Vehicle Identification Number ^ Dealership P/A code Dealership address The DOR/COR for this program is 50311. This number identifies parts ordered for this recall through the Special Service Support Center. DEALER PRICE For latest prices refer to DOES II. PARTS RETENTION AND RETURN Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures. EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information OVERVIEW This document details the procedure for replacing the fresh air inlet hose connector with an elbow assembly for the evaporative emissions (EVAP) canister. NOTE! Less than 15% of the affected vehicles may arrive at the dealership with the fresh air inlet hose disconnected from the wheel well splash shield. The evaporative emissions canister assembly must be replaced on these vehicles. Call the Special Service Support Center if replacement of the EVAP canister is required. See Evaporative Emissions Canister Assembly Replacement in this document for replacement procedures. DO NOT REPLACE the evaporative emissions canister if the vehicle arrives with the hose attached to the wheel well splash shield. FRESH AIR INLET HOSE CONNECTOR REPLACEMENT 1. Disconnect the EVAP canister fresh air inlet hose connector from the opening in the driver-side rear wheel well splash shield. See Figure 1. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > Recalls: > 03E05 > Jan > 04 > Recall - EVAP Fresh Air Hose Defect > Page 4000 2. Measure 12.7 mm (0.5 in.) from the bulge in the fresh air inlet hose and, using an appropriate hose cutter, cut the end of the hose off and discard. Make sure no debris falls into the hose. See Figure 2. 3. Install the new fresh air inlet hose elbow assembly into the hose and position it through the splash shield opening. 4. CAUTION: A restriction of air flow in the fresh air inlet hose may result in a slow fuel fill condition. Make sure the fresh air inlet hose is not pinched after tie strap installation. Secure the fresh air inlet hose to the fuel tank breather tube with a tie strap as indicated. See Figure 3. 5. Proceed to Authorized Modifications Label and Proof of Correction Certificate in this document. EVAPORATIVE EMISSIONS CANISTER ASSEMBLY REPLACEMENT NOTE! Call the Special Service Support Center if replacement of the EVAP canister is required. NOTE! Perform this procedure only if the vehicle arrived at the dealership with the fresh air inlet hose disconnected from the wheel well splash shield 1. Disconnect the battery negative cable. 2. Lower and remove the spare tire. 3. Raise the vehicle on a hoist. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > Recalls: > 03E05 > Jan > 04 > Recall - EVAP Fresh Air Hose Defect > Page 4001 4. Remove the five (5) EVAP canister assembly mounting bolts. See Figure 4. 5. Position the EVAP canister so you can access and disconnect the vapor hose from the passenger side of the EVAP canister, then the vent solenoid electrical connector, the wiring harness pin-type retainer and the vapor hose from the driver side of the EVAP canister. Once all the items are disconnected, remove the EVAP canister from the vehicle. See Figure 5. 6. Connect the vapor hose, wiring harness pin-type retainer and the vent solenoid electrical connector to the driver side of the new EVAP canister. Then connect the vapor hose to the passenger side of new EVAP canister. 7. Install the five (5) canister assembly mounting bolts. Tighten the bolts to 10 Nm (89 lb-in). 8. Lower the vehicle. 9. Position and raise the spare tire. 10. Connect the battery negative cable. 11. Perform an Evaporative Emissions System Leak Test as follows: a) CAUTION: The evaporative emission system must not be pressurized to more than 3.48 kPa (1.03 in Hg) or damage to the evaporative Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > Recalls: > 03E05 > Jan > 04 > Recall - EVAP Fresh Air Hose Defect > Page 4002 emission system may occur. Connect the Evaporative Emission System Leak Tester 310-F007 (134-00056 or equivalent) to the evaporative test port. b) NOTE: The ignition switch must be in the Key ON/Engine OFF position. c) Using WDS, NGS or equivalent, apply 12 volts to the canister vent solenoid. d) Pressurize the evaporative emissions system to 3.48 kPa (1.03 inHg). e) Monitor the system for two (2) minutes. If pressure falls below 2.0 kPa (0.6 inHg), the system has failed the leak test. f) Repair any leaks as necessary. (NOTE: Any repairs not related directly to the EVAP canister assembly replacement are not covered by this program.) g) Repeat the Evaporative Emissions System Leak Test until the system remains above 2.0 kPa (0.6 inHg) after the last test period. 12. Proceed to Authorized Modifications Label and Proof of Correction Certificate in this document. AUTHORIZED MODIFICATIONS LABEL AND PROOF OF CORRECTION CERTIFICATE 1. Obtain and prepare an Authorized Modifications Label. Write your P&A; code, date of repair, the program type and number, and either "EVAP CANISTER FRESH AIR INLET HOSE MODIFIED" or "EVAP CANISTER FRESH AIR INLET HOSE MODIFIED AND EVAP CANISTER REPLACED" in the space provided. See Figure 6. 2. Apply the label to a clean area adjacent to the Vehicle Emissions Control Information (VECI) label, then cover it with a clear plastic decal shield. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > Recalls: > 03E05 > Jan > 04 > Recall - EVAP Fresh Air Hose Defect > Page 4003 3. Provide California and Massachusetts owners with a "Vehicle Emission Recall - Proof of Correction" certificate. See Figure 7. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > Recalls: > 03E05 > Jan > 04 > Recall - EVAP Fresh Air Hose Defect > Page 4004 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > Recalls: > 03E05 > Jan > 04 > Recall - EVAP Fresh Air Hose Defect > Page 4005 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > Recalls: > 03E05 > Jan > 04 > Recall - EVAP Fresh Air Hose Defect > Page 4006 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > Recalls: > 03E05 > Jan > 04 > Recall - EVAP Fresh Air Hose Defect > Page 4007 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > Recalls: > 03E05 > Jan > 04 > Recall - EVAP Fresh Air Hose Defect > Page 4008 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > Component Information > Specifications Transmission Speed Sensor: Specifications Vehicle speed sensor bolt ......................................................................................................................................................... 11-13 Nm (98-115 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporative Emissions Hose: > 07-20-5 > Oct > 07 > Recalls for Evaporative Emissions Hose: > 03E05 > Jan > 04 > Recall - EVAP Fresh Air Hose Defect Technical Service Bulletin # 03E05 Date: 040101 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporative Emissions Hose: > 07-20-5 > Oct > 07 > Recalls for Evaporative Emissions Hose: > 03E05 > Jan > 04 > Recall - EVAP Fresh Air Hose Defect > Page 4020 Attachment I - Administrative Information Emissions Recall 03E05 Certain 2002 and 2003 MY Explorer Sport Trac Vehicles Evaporative Emissions Canister Fresh Air Inlet Hose Connector Replacement OASIS ACTIVATED? Yes FSA VIN LIST ACTIVATED? Yes NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states provinces and countries. Accordingly you must limit the use of this listing to the follow-up necessary to complete this action. STOCK VEHICLES Correct all affected stock vehicles before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the owner a copy of the Customer Notification Letter and schedule a service date. ^ Also correct other affected vehicles identified in OASIS which are brought to your dealership. RELATED DAMAGE Related damage claims are not approved for this program. ADDITIONAL LABOR TIME Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporative Emissions Hose: > 07-20-5 > Oct > 07 > Recalls for Evaporative Emissions Hose: > 03E05 > Jan > 04 > Recall - EVAP Fresh Air Hose Defect > Page 4021 ^ This repair will require no additional labor time to complete. Claims submitted with "MT" labor will not be accepted for reimbursement. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition call the Special Service Support Center. OWNER REFUNDS ^ Ford Motor Company will only refund owner-paid repairs related to this recall that were made before the date of the Customer Notification Letter (or after the date of the letter if an emergency repair was made away from the servicing dealer). Refund claims that include other non-covered repairs or those judged by Ford to be excessive will not be accepted for reimbursement. ^ This recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close out the VIN for this recall. ^ Refund Claiming Information. (Submit on separate repair line) - Program Code: 03E05 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hr. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION The Evaporative Emissions Fresh Air Inlet Hose Elbow Assembly (9S327) will not be direct shipped for this recall. Order this part through the normal order processing channels. ADDITIONAL PARTS REQUIREMENTS / ORDERING INFORMATION NOTE: This only applies to vehicles that arrive at the dealership with the fresh air inlet hose disconnected. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporative Emissions Hose: > 07-20-5 > Oct > 07 > Recalls for Evaporative Emissions Hose: > 03E05 > Jan > 04 > Recall - EVAP Fresh Air Hose Defect > Page 4022 Dealers must call the Special Service Support Center prior to the repair, if replacement of the EVAP canister assembly is required. Inform the representative you are calling in regard to Emissions Recall 03E05. Be prepared to provide the information shown. ^ Vehicle Identification Number ^ Dealership P/A code Dealership address The DOR/COR for this program is 50311. This number identifies parts ordered for this recall through the Special Service Support Center. DEALER PRICE For latest prices refer to DOES II. PARTS RETENTION AND RETURN Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures. EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information OVERVIEW This document details the procedure for replacing the fresh air inlet hose connector with an elbow assembly for the evaporative emissions (EVAP) canister. NOTE! Less than 15% of the affected vehicles may arrive at the dealership with the fresh air inlet hose disconnected from the wheel well splash shield. The evaporative emissions canister assembly must be replaced on these vehicles. Call the Special Service Support Center if replacement of the EVAP canister is required. See Evaporative Emissions Canister Assembly Replacement in this document for replacement procedures. DO NOT REPLACE the evaporative emissions canister if the vehicle arrives with the hose attached to the wheel well splash shield. FRESH AIR INLET HOSE CONNECTOR REPLACEMENT 1. Disconnect the EVAP canister fresh air inlet hose connector from the opening in the driver-side rear wheel well splash shield. See Figure 1. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporative Emissions Hose: > 07-20-5 > Oct > 07 > Recalls for Evaporative Emissions Hose: > 03E05 > Jan > 04 > Recall - EVAP Fresh Air Hose Defect > Page 4023 2. Measure 12.7 mm (0.5 in.) from the bulge in the fresh air inlet hose and, using an appropriate hose cutter, cut the end of the hose off and discard. Make sure no debris falls into the hose. See Figure 2. 3. Install the new fresh air inlet hose elbow assembly into the hose and position it through the splash shield opening. 4. CAUTION: A restriction of air flow in the fresh air inlet hose may result in a slow fuel fill condition. Make sure the fresh air inlet hose is not pinched after tie strap installation. Secure the fresh air inlet hose to the fuel tank breather tube with a tie strap as indicated. See Figure 3. 5. Proceed to Authorized Modifications Label and Proof of Correction Certificate in this document. EVAPORATIVE EMISSIONS CANISTER ASSEMBLY REPLACEMENT NOTE! Call the Special Service Support Center if replacement of the EVAP canister is required. NOTE! Perform this procedure only if the vehicle arrived at the dealership with the fresh air inlet hose disconnected from the wheel well splash shield 1. Disconnect the battery negative cable. 2. Lower and remove the spare tire. 3. Raise the vehicle on a hoist. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporative Emissions Hose: > 07-20-5 > Oct > 07 > Recalls for Evaporative Emissions Hose: > 03E05 > Jan > 04 > Recall - EVAP Fresh Air Hose Defect > Page 4024 4. Remove the five (5) EVAP canister assembly mounting bolts. See Figure 4. 5. Position the EVAP canister so you can access and disconnect the vapor hose from the passenger side of the EVAP canister, then the vent solenoid electrical connector, the wiring harness pin-type retainer and the vapor hose from the driver side of the EVAP canister. Once all the items are disconnected, remove the EVAP canister from the vehicle. See Figure 5. 6. Connect the vapor hose, wiring harness pin-type retainer and the vent solenoid electrical connector to the driver side of the new EVAP canister. Then connect the vapor hose to the passenger side of new EVAP canister. 7. Install the five (5) canister assembly mounting bolts. Tighten the bolts to 10 Nm (89 lb-in). 8. Lower the vehicle. 9. Position and raise the spare tire. 10. Connect the battery negative cable. 11. Perform an Evaporative Emissions System Leak Test as follows: a) CAUTION: The evaporative emission system must not be pressurized to more than 3.48 kPa (1.03 in Hg) or damage to the evaporative Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporative Emissions Hose: > 07-20-5 > Oct > 07 > Recalls for Evaporative Emissions Hose: > 03E05 > Jan > 04 > Recall - EVAP Fresh Air Hose Defect > Page 4025 emission system may occur. Connect the Evaporative Emission System Leak Tester 310-F007 (134-00056 or equivalent) to the evaporative test port. b) NOTE: The ignition switch must be in the Key ON/Engine OFF position. c) Using WDS, NGS or equivalent, apply 12 volts to the canister vent solenoid. d) Pressurize the evaporative emissions system to 3.48 kPa (1.03 inHg). e) Monitor the system for two (2) minutes. If pressure falls below 2.0 kPa (0.6 inHg), the system has failed the leak test. f) Repair any leaks as necessary. (NOTE: Any repairs not related directly to the EVAP canister assembly replacement are not covered by this program.) g) Repeat the Evaporative Emissions System Leak Test until the system remains above 2.0 kPa (0.6 inHg) after the last test period. 12. Proceed to Authorized Modifications Label and Proof of Correction Certificate in this document. AUTHORIZED MODIFICATIONS LABEL AND PROOF OF CORRECTION CERTIFICATE 1. Obtain and prepare an Authorized Modifications Label. Write your P&A; code, date of repair, the program type and number, and either "EVAP CANISTER FRESH AIR INLET HOSE MODIFIED" or "EVAP CANISTER FRESH AIR INLET HOSE MODIFIED AND EVAP CANISTER REPLACED" in the space provided. See Figure 6. 2. Apply the label to a clean area adjacent to the Vehicle Emissions Control Information (VECI) label, then cover it with a clear plastic decal shield. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporative Emissions Hose: > 07-20-5 > Oct > 07 > Recalls for Evaporative Emissions Hose: > 03E05 > Jan > 04 > Recall - EVAP Fresh Air Hose Defect > Page 4026 3. Provide California and Massachusetts owners with a "Vehicle Emission Recall - Proof of Correction" certificate. See Figure 7. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporative Emissions Hose: > 07-20-5 > Oct > 07 > Recalls for Evaporative Emissions Hose: > 03E05 > Jan > 04 > Recall - EVAP Fresh Air Hose Defect > Page 4027 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporative Emissions Hose: > 07-20-5 > Oct > 07 > Recalls for Evaporative Emissions Hose: > 03E05 > Jan > 04 > Recall - EVAP Fresh Air Hose Defect > Page 4028 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporative Emissions Hose: > 07-20-5 > Oct > 07 > Recalls for Evaporative Emissions Hose: > 03E05 > Jan > 04 > Recall - EVAP Fresh Air Hose Defect > Page 4029 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporative Emissions Hose: > 07-20-5 > Oct > 07 > Recalls for Evaporative Emissions Hose: > 03E05 > Jan > 04 > Recall - EVAP Fresh Air Hose Defect > Page 4030 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporative Emissions Hose: > 07-20-5 > Oct > 07 > Recalls for Evaporative Emissions Hose: > 03E05 > Jan > 04 > Recall - EVAP Fresh Air Hose Defect > Page 4031 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative System Service Port > Component Information > Service and Repair Evaporative System Service Port: Service and Repair REMOVAL 1. Remove the clip. 2. Disconnect the hoses. 3. Remove the test port assembly. ^ Disconnect the fitting. ^ Remove the test port assembly. INSTALLATION 1. To install, reverse the removal procedure. ^ Leak test the evaporative emissions system. See: Testing and Inspection/Component Tests and General Diagnostics/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. See: Testing and Inspection/Component Tests and General Diagnostics/Evaporative Emission Repair Verification Drive Cycle Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Diagrams Connector View C450 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Diagrams > Page 4038 Leak Detection Valve: Service Precautions WARNING: ^ THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND CAN BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Diagrams > Page 4039 Leak Detection Valve: Description and Operation Canister Vent Solenoid Typical Canister Vent (CV) Solenoid During the Enhanced EVAP System test monitor, the Canister Vent (CV) solenoid (Figure 99) seals the EVAP canister from atmospheric pressure. This allows the EVAP canister purge valve to obtain the target vacuum in the fuel tank during the monitor run. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Service and Repair > Vehicles After Before 03/2002 Leak Detection Valve: Service and Repair Vehicles After Before 03/2002 REMOVAL WARNING: ^ THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, WHICH CAN CAUSE A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUEFIED FUEL ARE PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY. ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND CAN BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY. 1. Remove the evaporative emissions canister. 2. Remove the emissions hose and remove the solenoid valve. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Lubricate all O-ring seals with O-ring seal lubricant. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Service and Repair > Vehicles After Before 03/2002 > Page 4042 Leak Detection Valve: Service and Repair Vehicles Built Before 03/2002 REMOVAL 1. Disconnect the battery ground cable. WARNING: THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 2. Remove the EVAP canister. 3. Remove the canister vent solenoid. INSTALLATION 1. To install, reverse removal procedure. ^ Leak test the EVAP system. See: Testing and Inspection/Component Tests and General Diagnostics/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. See: Testing and Inspection/Component Tests and General Diagnostics/Evaporative Emission Repair Verification Drive Cycle Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Liquid Vapor Separator, Evaporative System > Component Information > Service Precautions Liquid Vapor Separator: Service Precautions WARNING: THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL ARE PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Liquid Vapor Separator, Evaporative System > Component Information > Service Precautions > Page 4046 Liquid Vapor Separator: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Lower the fuel tank. WARNING: THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL ARE PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 3. Remove the EVAP canister tube from the fuel vapor vent valve. 4. Remove the fuel vapor vent valve. ^ Press down and rotate the fuel vapor vent valve counterclockwise and remove it from the fuel tank. INSTALLATION 1. To install, reverse removal procedure. ^ Leak test the evaporative emissions system. See: Testing and Inspection/Component Tests and General Diagnostics/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. See: Testing and Inspection/Component Tests and General Diagnostics/Evaporative Emission Repair Verification Drive Cycle Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Refueling Vapor Recovery System > System Information > Description and Operation Refueling Vapor Recovery System: Description and Operation On-Board Refueling Vapor Recovery (ORVR) Evaporative Emission (EVAP) System On-Board Refueling Vapor Recovery Evaporative Emission System On-Board Refueling Vapor Recovery Evaporative Emission System Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Refueling Vapor Recovery System > System Information > Description and Operation > Page 4050 On-Board Refueling Vapor Recovery Evaporative Emission System The basic elements forming the ORVR system (Figure 101), (Figure 102) and (Figure 103) operation are as follows when fuel is dispensed: 1. The fuel filler pipe forms a seal to prevent vapors from escaping the fuel tank, while liquid is entering the fuel tank (liquid in the one inch diameter tube blocks vapors from rushing back up the fuel filler pipe). 2. A fuel vapor control valve controls the flow of vapors out of the fuel tank (valve closes when liquid level reaches a height associated with the fuel tank usable capacity). This valve accomplishes the following: a. Limits the total amount of fuel that can be dispensed into the fuel tank. b. Prevents liquid gasoline from exiting the fuel tank when submerged (and also when tipped well beyond a horizontal plane as part of the vehicle roll-over protection in road accidents). c. Minimizes vapor flow resistance during anticipated refueling conditions. 3. Fuel vapor tubing connects the fuel vapor control valve to the EVAP canister. This routes the fuel tank vapors (displaced by the incoming liquid) to the EVAP canister. 4. A check valve in the bottom of the fuel filler pipe prevents liquid from rushing back up the fuel filler pipe during the liquid flow variations associated with the filler nozzle shut-off. Between refueling events, the EVAP canister is purged with fresh air so that it may be used again to store vapors accumulated engine soaks or subsequent refueling events. The vapors drawn off of the carbon in the EVAP canister are consumed in the engine. Refer to Evaporative Emissions System for information on the following Evaporative Emission System components: liquid/vapor fuel discriminator, fuel filler pipe check valve, fill limit valve assembly, fill limit vent valve assembly, fuel filler pipe flapper valve, fuel vapor control valve (fuel tank mounted), ORVR T-connector assembly and EVAP canister. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Diagrams Connector View C1072 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Diagrams > Page 4055 EGR Electronic Vacuum Regulator Solenoid: Description and Operation EGR Vacuum Regulator Solenoid EGR Vacuum Regulator Solenoid Test Graph EGR Vacuum Regulator Solenoid Data Chart The EGR vacuum regulator solenoid (Figure 88) is an electromagnetic device which is used to regulate the vacuum supply to the EGR valve. The solenoid contains a coil which magnetically controls the position of a disc to regulate the vacuum. As the duty cycle to the coil increases, the vacuum signal passed through the solenoid to the EGR valve also increases. Vacuum not directed to the EGR valve is vented through the solenoid vent to atmosphere. Note that at 0% duty cycle (no electrical signal applied), the EGR vacuum regulator solenoid allows some vacuum to pass, but not enough to open the EGR valve. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Diagrams > Page 4056 EGR Electronic Vacuum Regulator Solenoid: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the Exhaust Gas Recirculation (EGR) vacuum regulator solenoid. 1 Disconnect the electrical connector. 2 Disconnect the vacuum lines. 3 Remove the nut. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Description and Operation EGR Tube: Description and Operation Orifice Tube Assembly Orifice Tube Assembly The orifice tube assembly (Figure 90) is a section of tubing connecting the exhaust system to the intake manifold. The assembly provides the flow path for the EGR to the intake manifold and also contains the metering orifice and two pressure pick-up tubes. The internal metering orifice creates a measurable pressure drop across it as the EGR valve opens and closes. This pressure differential across the orifice is picked up by the differential pressure feedback EGR sensor which provides feedback to the PCM. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Description and Operation > Page 4060 EGR Tube: Service and Repair REMOVAL 1. Remove the lower Exhaust Gas Recirculation (EGR) valve tube. 1 Disconnect the tube fittings. 2 Disconnect the differential pressure feedback EGR hoses. 3 Remove the tube. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > Differential Pressure Feedback EGR System EGR Valve: Description and Operation Differential Pressure Feedback EGR System Exhaust Gas Recirculation Valve EGR Valve Test Graph The EGR valve (Figure 89) in the Differential Pressure Feedback EGR system is a conventional, vacuum-actuated EGR valve. The valve increases or decreases the flow of exhaust gas recirculation. As vacuum applied to the EGR valve diaphragm overcomes the spring force, the valve begins to open. As the vacuum signal weakens, at 5.4 kPa (1.6 in-Hg) or less, the spring force closes the valve. The EGR valve is fully open at about 15 kPa (4.5 in-Hg). Since EGR flow requirement varies greatly, providing service specifications on flow rate is impractical. The on-board diagnostic system monitors the EGR valve function and triggers a Diagnostic Trouble Code if the test criteria is not met. The EGR valve flow rate is not measured directly as part of the field diagnostic procedures. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > Differential Pressure Feedback EGR System > Page 4065 EGR Valve: Description and Operation Electric Motor EGR System (EEGR) Electric Motor EGR System (EEGR) Highlights of the Electric System ^ EEGR valve is activated by an electric stepper motor not a vacuum motor (Rear of engine block). ^ No vacuum diaphragm is used. ^ No DPFE sensor is used. ^ No Orifice Tube/Assembly is used. ^ No EGR vacuum regulator solenoid is used. ^ A new Manifold Absolute Pressure (MAP) sensor is used (called Thermal Manifold Absolute Pressure (TMAP) but the temperature function is not used at this time) (located on top of the valve cover). ^ Engine coolant is routed through the assembly extending durability of the electric motor. Overview Electric EGR System The electric EGR system uses exhaust gas recirculation to control the Oxides Of Nitrogen (NOx) emissions just like vacuum operated systems. The only difference is the way in which the exhaust gas is controlled. The Electric EGR system consists of an electric motor/EGR valve integrated assembly, a PCM, and connecting wiring. Additionally a MAP sensor is also required. Operation of the system is as follows (Figure 91): 1. The EEGR system receives signals from the Engine Coolant Temperature (ECT) or Cylinder Head Temperature (CHT) sensor, throttle position (TP) sensor, mass air flow (MAF) sensor, crankshaft position (CKP) sensor and the manifold absolute pressure (MAP) sensor to provide information on engine operating conditions to the PCM. The engine must be warm, stable and running at a moderate load and rpm before the EEGR system is activated. The PCM will deactivate EGR during idle, extended wide open throttle or whenever a failure is detected in an EEGR component or EGR required input. 2. The PCM calculates the desired amount of EGR for a given set of engine operating conditions. 3. The PCM in turn will output signals to the EEGR motor to move (advance or retract) a certain number of discrete steps. The electric stepper motor will directly actuate the EGR valve, independent of engine vacuum. The EGR valve is commanded from 0 to 52 discrete increments or "steps" to get the EGR valve from a fully closed to full or partially open position. The position of the EGR valve determines the EGR flow. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > Differential Pressure Feedback EGR System > Page 4066 4. A MAP sensor is used to measure variations in manifold pressure as exhaust gas recirculation is introduced into the intake manifold. Variations in EGR being used will correlate to the MAP signal (increasing EGR will increase manifold pressure values). Hardware Electric EGR Motor/Valve Assembly Electric EGR The electric EGR valve (Figure 92) and (Figure 93) is a water cooled motor/valve assembly. The motor is commanded to move in 52 discrete steps as it acts directly on the the EGR valve. The position of the valve determines the rate of EGR. The built in spring works to close the valve (against Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > Differential Pressure Feedback EGR System > Page 4067 the motor opening force). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > Page 4068 EGR Valve: Service and Repair REMOVAL 1. Disconnect the Exhaust Gas Recirculation (EGR) valve. ^ Disconnect the vacuum line. ^ Disconnect the EGR valve tube fitting. 2. Remove the EGR valve bolts and the EGR valve. ^ Discard the gasket. INSTALLATION 1. To install, reverse the removal procedure. ^ Carefully clean the EGR valve sealing surfaces. ^ Install a new EGR valve gasket. NOTE: The EGR valve sealing surfaces are soft metals. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4077 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4078 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4079 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4080 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4081 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4087 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4088 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4089 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4090 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4091 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4096 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4097 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4098 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4104 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4105 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4106 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4107 View 151-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4108 Connector View C1068 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4109 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR Sensor Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 86) is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Tube Mounted Differential Pressure Feedback EGR Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4110 Tube Mounted Differential Pressure Feedback EGR Sensor The tube mounted differential pressure feedback EGR sensor (Figure 87) is identical in operation as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the underside of the sensor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4111 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the differential pressure feedback Exhaust Gas Recirculation (EGR). 1 Disconnect the electrical connector. 2 Disconnect the hoses. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Service and Repair Positive Crankcase Ventilation Valve: Service and Repair REMOVAL 1. Remove the vacuum hose. 2. Remove the Positive Crankcase Ventilation (PCV) valve. 1 Disconnect the coolant hoses from the PCV valve. 2 Unlock and remove the PCV valve from the valve cover. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Relays and Modules - Emission Control Systems > Air Injection Pump Relay > Component Information > Description and Operation Air Injection Pump Relay: Description and Operation Solid State Relay Solid State Relay The solid state relay (Figure 124) switches the high current required for operation of the electric AIR pump. Input control to the solid state relay comes from the powertrain control module (PCM). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4129 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4130 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4131 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4132 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4133 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4139 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4140 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4141 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4142 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4143 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4148 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4149 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4150 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4156 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4157 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4158 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4159 View 151-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4160 Connector View C1068 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4161 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR Sensor Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 86) is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Tube Mounted Differential Pressure Feedback EGR Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4162 Tube Mounted Differential Pressure Feedback EGR Sensor The tube mounted differential pressure feedback EGR sensor (Figure 87) is identical in operation as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the underside of the sensor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4163 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the differential pressure feedback Exhaust Gas Recirculation (EGR). 1 Disconnect the electrical connector. 2 Disconnect the hoses. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Technician Safety Information Fuel Pressure Test Port: Technician Safety Information WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Technician Safety Information > Page 4170 Fuel Pressure Test Port: Vehicle Damage Warnings CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 4171 Fuel Pressure Test Port: Description and Operation Pressure Test Point There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. ON VEHICLES NOT EQUIPPED WITH A SCHRADER VALVE, USE ROTUNDA FUEL PRESSURE TEST KIT #134-R0087 OR EQUIVALENT. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 4172 Fuel Pressure Test Port: Service and Repair REMOVAL WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Remove the fuel injection supply manifold. 2. Remove the two bolts, the pressure relief valve and the O-ring seals. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. NOTE: Lubricate the new O-ring seals with clean engine oil to aid installation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions > Page 4176 Fuel Pressure Release: Service and Repair Fuel Pressure Gauge SPECIAL TOOL(S) WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Disconnect the battery ground cable. 2. Remove the Schrader valve cap and attach the Fuel Pressure Gauge. 3. Open the manual valve on the Fuel Pressure Gauge slowly to relieve the fuel system pressure. This may drain fuel from the system. Drain the fuel into a suitable container. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions > Page 4177 Fuel Pressure Gauge Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > With Automatic Transmission Idle Speed: Specifications With Automatic Transmission With Flex Fuel Hot Idle ................................................................................................................................................ ......................................................... 800 - 900 RPM With Gasoline Hot Idle ................................................................................................................................................ ......................................................... 760 - 780 RPM Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > With Automatic Transmission > Page 4182 Idle Speed: Specifications With Manual Transmission Hot Idle ................................................................................................................................................ ......................................................... 760 - 880 RPM Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications Torque Specifications Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications > Page 4186 Accelerator Pedal: Description and Operation The throttle is controlled by an accelerator cable attached to the accelerator pedal and shaft assembly. The accelerator pedal and shaft should travel smoothly from the idle position to the wide open throttle position. Hesitation or binding should not be experienced at any portion of the accelerator pedal and shaft travel. Surrounding components such as wiring, hoses, sound insulator and floor carpet must not contact the sliding inner member of the accelerator cable or interfere with the accelerator pedal and shaft. The acceleration control consists of an accelerator pedal and cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Accelerator Pedal: Initial Inspection and Diagnostic Overview NOTE: Care should be exercised when carrying out repair on or around the accelerator pedal linkage and controls. 1. Inspect the accelerator pedal and shaft and attaching linkage for damage or distortion which would bind or limit accelerator travel. 2. Inspect the accelerator cable for kinks or fraying which may cause binding. 3. Inspect the engine idle speed adjustment to make sure of the correct idle speed specification after any accelerator linkage adjustment or repair. 4. Inspect throttle body for excessive wear or damage. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4189 SYMPTOM CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Cable Accelerator Pedal: Service and Repair Cable REMOVAL 1. Disconnect the cable from the accelerator pedal. 2. Collapse the clips at the dash panel and push the cable through the dash panel into the engine compartment. 3. Remove the bolts and the accelerator cable snow shield. 4. Disconnect the cable from the throttle body. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Cable > Page 4192 5. Remove the accelerator cable. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Cable > Page 4193 Accelerator Pedal: Service and Repair Pedal REMOVAL 1. Disconnect the cable from the accelerator pedal 2. Remove the screw and the accelerator pedal. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Component Information > Service and Repair Air Cleaner Housing: Service and Repair REMOVAL 1. Disconnect the air cleaner assembly. ^ Loosen the clamp and disconnect the outlet tube. ^ Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Remove the lower air cleaner assembly. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations View 151-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 4200 Connector View C128 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 4201 Mass Air Flow Sensor: Service Precautions CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 4202 Mass Air Flow Sensor: Description and Operation Mass Air Flow Sensor Typical Mass Air Flow (MAF) Sensor Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire Terminals The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 35). If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio (Figure 36). This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 4203 Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated intake air temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar, Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 4204 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Loosen the air cleaner outlet tube clamp and position the tube aside. 3. Remove the four bolts and the MAF sensor. CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle Technical Service Bulletin # 03-3-5 Date: 030217 Engine Controls - No Start/Hard Start/Rough Idle Article No. 03-3-5 02/17/03 DRIVEABILITY - IDLE AIR CONTROL (IAC) VALVE DIAGNOSTIC SERVICE TIPS FORD: 2000-2003 TAURUS 2002 THUNDERBIRD 2000-2003 EXPLORER, RANGER 2001-2003 EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 2000-2002 LS MERCURY: 2000-2003 SABLE, MOUNTAINEER ISSUE Some vehicles, may exhibit drivability conditions. These may include: ^ No start Difficult to start Stall ^ Low idle ^ Rough idle ^ High idle ^ Hesitation/surge while accelerating or at steady speed These conditions may be intermittent with no Diagnostic Trouble Codes (DTC) and no Malfunction Indicator Lamp (MIL). In some cases DTC and MIL may be evident. ACTION Trouble cannot be identified with 95% of returned Idle Air Control (IAC) valves. The following procedure is supplemental information to normal diagnostics to facilitate accurate identification of malfunctioning valves. These symptoms would include engine stall, hard start, crank/no start, idling problems, and Idle Speed Control System related DTC's. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4213 If the service writer uses the worksheet (Figure 2) for all drivability concerns including stalls it will assist the technician making a correct repair the first time. Perform normal diagnostics. SERVICE INFORMATION NOTE Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4214 IT MAY NOT BE POSSIBLE TO DUPLICATE THE CUSTOMER CONCERN. ALTHOUGH THE CONDITION MAY NOT BE DUPLICATED, IT IS RECOMMENDED THAT ANY EVALUATION OF THE IAC VALVE BE DONE IN ACCORDANCE WITH THE FOLLOWING SERVICE PROCEDURE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 602300 603300, 607000, 607400, 607700, 608000, 608400, 611000, 618400, 619400, 698298 Disclaimer IAC Diagnostic Service Tips - General Never clean an IAC valve. Carburetor cleaners and other cleaning agents may temporarily repair the drivability concern, but the long-term functionality of the valve is compromised. For all drivability concerns, make certain the service writer obtains as much information as possible from the customer as to the conditions causing drivability concern. Attached is a drivability concern check off sheet (Figure 2) that if used, can help reduce the time required to diagnose a vehicle. NOTE IF THE ENGINE STALLED WHILE THE VEHICLE WAS IN GEAR AND MOVING THE POSSIBILITY OF THE IAC VALVE CAUSING THIS IS UNLIKELY UNLESS IT OCCURRED ON DECELERATION. Use the following Supplemental information for 3.0L 4V Duratec Engines, in the Taurus/Sable, and Lincoln LS. 1. Use the following conditions for the test described below: ^ Transmission in park ^ Engine temperature should be at least 190° F (88°C) ^ All accessories should be off steering wheel in the center position ^ EGVR and EVAPDUTY CYCLE at zero, if the vehicle has an EGR system ^ Short and long term fuel trims less than 15% ^ At stabilized engine speed (RPM) and temperature (hot idle) per the Powertrain Control Emission Diagnostics (PC/ED) manual, verify the IAC duty cycle is within reference values called out in the chart in this TSB. NOTE IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES. If the Duty Cycle is out of specification, proceed with the following steps: 1. Ensure that there is no purge flow. 2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is running and observe the IAC duty cycle and engine performance. Should abnormalities be observed, repair the harness as required. 3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times. If the duty cycle remains high, replace IAC valve. 4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC diagnostic service tip for DTC 1506 and other high idle concerns. Use the following Supplemental Information for the 3.9L Lincoln LS and Thunderbird. 1. Use the following conditions for the test described below: ^ Transmission in park Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4215 ^ Engine idle at approximately 650 RPM ^ Engine temperature should be at least 190° F (88° C) ^ All accessories and the engine cooling fan should be off ^ Steering wheel in the center position ^ EGRVR and EVAPDUTY CYCLE are zero ^ Short and long term fuel trims less than 15% NOTE IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES. NOTE IT IS EXTREMELY IMPORTANT TO CHECK THE IAC DUTY CYCLE WHEN THE RPM IS AT 650 RPM. EVEN 700 RPM IS TOO HIGH FOR CHECKING the IAC VALVE DUTY CYCLE UNDER THESE CONDITIONS. IF THE RPM IS OVER 650 RPM, MOMENTARILY OPENING AND CLOSING THE THROTTLE AND A SHORT EQUILIBRATION TIME WILL LOWER THE RPM. At stabilized engine speed and temperature, verify that the IAC duty cycle is between 27-36% with no purge flow (EVAPV duty cycle is 0%). If the Duty Cycle is out of specification, proceed with the following steps: 1. Ensure there is no purge flow. 2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is running and observe the IAC duty cycle and engine performance. Should abnormalities be observed, repair the harness as required. 3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times. If the duty cycle remains high, replace IAC valve. 4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC diagnostic service tip for DTC 1506 and other high idle concerns. NOTE IF THE ORIGINAL IAC VALVE WAS WITHIN DUTY CYCLE SPECIFICATION OR THE DUTY CYCLE REMAINS OUT OF SPECIFICATIONS AFTER IAC VALVE REPLACEMENT FURTHER DIAGNOSTICS ARE REQUIRED TO ADDRESS THE CUSTOMER CONCERN. Use the following Supplemental Information for 4.0L SOHC Engines In the Ranger, Explorer, Mountaineer, Explorer Sport and Explorer Sport Trac. If no DTC's present check the following items in this order before examining the IAC valve: ^ BARO Hz reading - Refer to Barometric Pressure Chart listed in this TSB ^ Battery and fuse box power lead ^ Ground wire attachments ^ Wiring (wiggle test) ^ PCM voltage ^ Vacuum leaks Examine AC valve under these conditions: ^ PCM updated to the latest available calibration ^ Transmission in park ^ Warm stabilized vehicle with engine temperature at least 190° F (88° C) ^ All accessories and cooling fan sh6uld be off Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4216 ^ Steering wheel in the center position ^ EGVR and EVAPDC at zero, if the vehicle has an EGR system ^ Short and long term fuel trims (less than 15) Perform the following steps in order: 1. Using either NGS or WDS bring up the following PIDS: IACTRIM, IACKAM2, IACKAM3. 2. Allow vehicle to idle until the IACTRIM PID is 0. NOTE IACTRIM ALWAYS TRIES TO GO TO 0. WHEN MOVING TOWARDS 0, THE IACKAM2 PID SHOULD BE CHANGING. IF IACKAM3 IS CHANGING, THEN THE AIR CONDITIONING SHOULD BE TURNED OFF. 3. If IACKAM2 is between -0.35 and +0.35 with IACTRIM=0, then the valve is operating properly at idle. The remainder of this TSB will help diagnose true root cause. 4. If IACKAM2 is not between -0.35 and +0.35, it is highly likely that the engine idle system (to include the throttle body and air intake system) -is not operating properly. NOTE FOR ALL VEHICLES PLEASE RECORD THE OBSERVED IAC DUTY CYCLE AND ENGINE RPM IN THE WARRANTY CLAIMS COMMENTS FOR THIS DIAGNOSTIC. IAC Diagnostic Service Tips - DTC 1506 (IAC Over Speed Error) and other High Idle Concerns: ^ There are two primary causes of high idle: 1. Damaged IAC valves and 2. Vacuum leaks ^ AC valves can be damaged from engine induction backfires. Many times the customer may not notice the induction backfire but will notice the high idle afterwards. Indications of valve damage can be a shiny, almost polished appearance in the interior of the valve and a dislocated Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4217 pintle. An IAC valve damaged by backfire should be replaced. Refer to Figure 1. ^ Inspect PCV system for leaks especially looking for cracks along any rubber elbow joints; also verify that the correct PCV valve is installed. ^ Inspect for vacuum hoses loose or disconnected from intended ports and connections. Induction backfire can loosen or disconnect vacuum hoses. ^ Two indicators can help you identify if a vacuum leak is present, even if the engine RPM appear normal in the service bay. If the duty cycle is below specification that is indicative that the engine is receiving too much air (from a vacuum leak) and the PCM is ordering the valve to close up to restrict flow. Another indication is fuel trim. Record the long term and short term fuel trim PIDS (LONGFT1, LONGFT2, SHORTFT1, etc.), if short term fuel trims are high (above specification) this is a possible indication of a vacuum leak, making the engine run lean, and the PCM is attempting to compensate. IAC Diagnostic Service Tips - DTC 1507 (IAC Under Speed Error) and Other Low Idle Concerns: ^ An under speed error may not necessarily be a fault with the IAC valve. A large friction load on the engine or obstruction in the air intake system could also reduce the engine RPMs. ^ There are four possible sources of friction load that can contribute to under speed error or low idle concerns. 1. Power Steering Load 2. Air Conditioning Load 3. Electrical Load 4. Automatic Transmission Torque Converter Load EAC Diagnostic Service Tips - Rough Idle Concerns: ^ Rough idle concerns are often a result of a lean running condition ^ Another possible cause is contamination build up on the MAF sensor EAC Diagnostic Service Tips - Engine Hard Start/Engine Crank-No Start ^ While performing diagnostics, the technician should ensure that the fuel system is working correctly for all engines with hard start/crank no-start complaints. ^ When diagnosing a mechanical return less fuel system, the following correction to the PC/ED pinpoint HC (4) diagnostic procedure should be used when performing the KEOE fuel pressure test: ^ Perform the KOEO fuel pressure test as specific in the PC/ED manual. ^ The fuel pressure should drop off no more than 10 psi from maximum pressure (no lower than 55 psi for a 65 psi max system or no lower than 45 psi for a 55 psi max system) within 5 minutes of the start of the test. ^ The fuel pressure should drop off to no less than 30 psi within 30 minutes of the start of the test. ^ For greatest accuracy, the service technician should read the fuel pressure as soon as possible after pump shut off, no more than 5 minutes after the start of the test. NOTE RETURNABLE AND ELECTRONIC RETURN LESS SYSTEMS SHOULD ALSO BE DIAGNOSED USING THE PROCEDURES LISTED FOR THEM IN PINPOINT TEST HC. IAC Diagnostic Service Tips - High Idle RPM at Start Up: ^ Most engines will have a temporary high idle at engine start up to allow for catalyst light off. If DTC 1506 is not present, this indicates that there is no fault present with the IAC. ^ A vehicle with very low odometer miles, may exhibit a higher than normal temporary startup fast idle (1600-2500 RPM that decreases slowly). No Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4218 repairs should be attempted because this is a normal temporary PCM calibration strategy to prevent spark plug fouling during plant/transportation operation. The calibration will permanently revert to its normal strategy after the PCM has seen its first 4 miles of continuous drive cycle. A brand new vehicle may accumulate some mileage without turning this strategy off if the drive cycle has been below 4 miles at a time. IAC Diagnostic Service Tips - EAC Valve Noise Issues For IAC valve noise concerns check for obstructed or potentially damaged IAC valve from backfire. NOTE Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4219 ON SOME NEWER MODEL YEAR VEHICLES THE REACTION SPEED OF THE EAC VALVE IS FAST ENOUGH THAT IT MIGHT MAKE A "POPPING" SOUND AS IT REACTS TO A LARGE IDLE LOAD. THIS IS A NORMAL CHARACTERISTIC AND NO ATTEMPTS SHOULD BE MADE IN AN EFFORT TO MODIFY THE PERFORMANCE OF THE IAC VALVE. IF POSSIBLE, COMPARE AGAINST A LIKE VEHICLE. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/-1 in.Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE, WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle Technical Service Bulletin # 03-3-5 Date: 030217 Engine Controls - No Start/Hard Start/Rough Idle Article No. 03-3-5 02/17/03 DRIVEABILITY - IDLE AIR CONTROL (IAC) VALVE DIAGNOSTIC SERVICE TIPS FORD: 2000-2003 TAURUS 2002 THUNDERBIRD 2000-2003 EXPLORER, RANGER 2001-2003 EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 2000-2002 LS MERCURY: 2000-2003 SABLE, MOUNTAINEER ISSUE Some vehicles, may exhibit drivability conditions. These may include: ^ No start Difficult to start Stall ^ Low idle ^ Rough idle ^ High idle ^ Hesitation/surge while accelerating or at steady speed These conditions may be intermittent with no Diagnostic Trouble Codes (DTC) and no Malfunction Indicator Lamp (MIL). In some cases DTC and MIL may be evident. ACTION Trouble cannot be identified with 95% of returned Idle Air Control (IAC) valves. The following procedure is supplemental information to normal diagnostics to facilitate accurate identification of malfunctioning valves. These symptoms would include engine stall, hard start, crank/no start, idling problems, and Idle Speed Control System related DTC's. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4225 If the service writer uses the worksheet (Figure 2) for all drivability concerns including stalls it will assist the technician making a correct repair the first time. Perform normal diagnostics. SERVICE INFORMATION NOTE Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4226 IT MAY NOT BE POSSIBLE TO DUPLICATE THE CUSTOMER CONCERN. ALTHOUGH THE CONDITION MAY NOT BE DUPLICATED, IT IS RECOMMENDED THAT ANY EVALUATION OF THE IAC VALVE BE DONE IN ACCORDANCE WITH THE FOLLOWING SERVICE PROCEDURE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 602300 603300, 607000, 607400, 607700, 608000, 608400, 611000, 618400, 619400, 698298 Disclaimer IAC Diagnostic Service Tips - General Never clean an IAC valve. Carburetor cleaners and other cleaning agents may temporarily repair the drivability concern, but the long-term functionality of the valve is compromised. For all drivability concerns, make certain the service writer obtains as much information as possible from the customer as to the conditions causing drivability concern. Attached is a drivability concern check off sheet (Figure 2) that if used, can help reduce the time required to diagnose a vehicle. NOTE IF THE ENGINE STALLED WHILE THE VEHICLE WAS IN GEAR AND MOVING THE POSSIBILITY OF THE IAC VALVE CAUSING THIS IS UNLIKELY UNLESS IT OCCURRED ON DECELERATION. Use the following Supplemental information for 3.0L 4V Duratec Engines, in the Taurus/Sable, and Lincoln LS. 1. Use the following conditions for the test described below: ^ Transmission in park ^ Engine temperature should be at least 190° F (88°C) ^ All accessories should be off steering wheel in the center position ^ EGVR and EVAPDUTY CYCLE at zero, if the vehicle has an EGR system ^ Short and long term fuel trims less than 15% ^ At stabilized engine speed (RPM) and temperature (hot idle) per the Powertrain Control Emission Diagnostics (PC/ED) manual, verify the IAC duty cycle is within reference values called out in the chart in this TSB. NOTE IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES. If the Duty Cycle is out of specification, proceed with the following steps: 1. Ensure that there is no purge flow. 2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is running and observe the IAC duty cycle and engine performance. Should abnormalities be observed, repair the harness as required. 3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times. If the duty cycle remains high, replace IAC valve. 4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC diagnostic service tip for DTC 1506 and other high idle concerns. Use the following Supplemental Information for the 3.9L Lincoln LS and Thunderbird. 1. Use the following conditions for the test described below: ^ Transmission in park Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4227 ^ Engine idle at approximately 650 RPM ^ Engine temperature should be at least 190° F (88° C) ^ All accessories and the engine cooling fan should be off ^ Steering wheel in the center position ^ EGRVR and EVAPDUTY CYCLE are zero ^ Short and long term fuel trims less than 15% NOTE IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES. NOTE IT IS EXTREMELY IMPORTANT TO CHECK THE IAC DUTY CYCLE WHEN THE RPM IS AT 650 RPM. EVEN 700 RPM IS TOO HIGH FOR CHECKING the IAC VALVE DUTY CYCLE UNDER THESE CONDITIONS. IF THE RPM IS OVER 650 RPM, MOMENTARILY OPENING AND CLOSING THE THROTTLE AND A SHORT EQUILIBRATION TIME WILL LOWER THE RPM. At stabilized engine speed and temperature, verify that the IAC duty cycle is between 27-36% with no purge flow (EVAPV duty cycle is 0%). If the Duty Cycle is out of specification, proceed with the following steps: 1. Ensure there is no purge flow. 2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is running and observe the IAC duty cycle and engine performance. Should abnormalities be observed, repair the harness as required. 3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times. If the duty cycle remains high, replace IAC valve. 4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC diagnostic service tip for DTC 1506 and other high idle concerns. NOTE IF THE ORIGINAL IAC VALVE WAS WITHIN DUTY CYCLE SPECIFICATION OR THE DUTY CYCLE REMAINS OUT OF SPECIFICATIONS AFTER IAC VALVE REPLACEMENT FURTHER DIAGNOSTICS ARE REQUIRED TO ADDRESS THE CUSTOMER CONCERN. Use the following Supplemental Information for 4.0L SOHC Engines In the Ranger, Explorer, Mountaineer, Explorer Sport and Explorer Sport Trac. If no DTC's present check the following items in this order before examining the IAC valve: ^ BARO Hz reading - Refer to Barometric Pressure Chart listed in this TSB ^ Battery and fuse box power lead ^ Ground wire attachments ^ Wiring (wiggle test) ^ PCM voltage ^ Vacuum leaks Examine AC valve under these conditions: ^ PCM updated to the latest available calibration ^ Transmission in park ^ Warm stabilized vehicle with engine temperature at least 190° F (88° C) ^ All accessories and cooling fan sh6uld be off Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4228 ^ Steering wheel in the center position ^ EGVR and EVAPDC at zero, if the vehicle has an EGR system ^ Short and long term fuel trims (less than 15) Perform the following steps in order: 1. Using either NGS or WDS bring up the following PIDS: IACTRIM, IACKAM2, IACKAM3. 2. Allow vehicle to idle until the IACTRIM PID is 0. NOTE IACTRIM ALWAYS TRIES TO GO TO 0. WHEN MOVING TOWARDS 0, THE IACKAM2 PID SHOULD BE CHANGING. IF IACKAM3 IS CHANGING, THEN THE AIR CONDITIONING SHOULD BE TURNED OFF. 3. If IACKAM2 is between -0.35 and +0.35 with IACTRIM=0, then the valve is operating properly at idle. The remainder of this TSB will help diagnose true root cause. 4. If IACKAM2 is not between -0.35 and +0.35, it is highly likely that the engine idle system (to include the throttle body and air intake system) -is not operating properly. NOTE FOR ALL VEHICLES PLEASE RECORD THE OBSERVED IAC DUTY CYCLE AND ENGINE RPM IN THE WARRANTY CLAIMS COMMENTS FOR THIS DIAGNOSTIC. IAC Diagnostic Service Tips - DTC 1506 (IAC Over Speed Error) and other High Idle Concerns: ^ There are two primary causes of high idle: 1. Damaged IAC valves and 2. Vacuum leaks ^ AC valves can be damaged from engine induction backfires. Many times the customer may not notice the induction backfire but will notice the high idle afterwards. Indications of valve damage can be a shiny, almost polished appearance in the interior of the valve and a dislocated Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4229 pintle. An IAC valve damaged by backfire should be replaced. Refer to Figure 1. ^ Inspect PCV system for leaks especially looking for cracks along any rubber elbow joints; also verify that the correct PCV valve is installed. ^ Inspect for vacuum hoses loose or disconnected from intended ports and connections. Induction backfire can loosen or disconnect vacuum hoses. ^ Two indicators can help you identify if a vacuum leak is present, even if the engine RPM appear normal in the service bay. If the duty cycle is below specification that is indicative that the engine is receiving too much air (from a vacuum leak) and the PCM is ordering the valve to close up to restrict flow. Another indication is fuel trim. Record the long term and short term fuel trim PIDS (LONGFT1, LONGFT2, SHORTFT1, etc.), if short term fuel trims are high (above specification) this is a possible indication of a vacuum leak, making the engine run lean, and the PCM is attempting to compensate. IAC Diagnostic Service Tips - DTC 1507 (IAC Under Speed Error) and Other Low Idle Concerns: ^ An under speed error may not necessarily be a fault with the IAC valve. A large friction load on the engine or obstruction in the air intake system could also reduce the engine RPMs. ^ There are four possible sources of friction load that can contribute to under speed error or low idle concerns. 1. Power Steering Load 2. Air Conditioning Load 3. Electrical Load 4. Automatic Transmission Torque Converter Load EAC Diagnostic Service Tips - Rough Idle Concerns: ^ Rough idle concerns are often a result of a lean running condition ^ Another possible cause is contamination build up on the MAF sensor EAC Diagnostic Service Tips - Engine Hard Start/Engine Crank-No Start ^ While performing diagnostics, the technician should ensure that the fuel system is working correctly for all engines with hard start/crank no-start complaints. ^ When diagnosing a mechanical return less fuel system, the following correction to the PC/ED pinpoint HC (4) diagnostic procedure should be used when performing the KEOE fuel pressure test: ^ Perform the KOEO fuel pressure test as specific in the PC/ED manual. ^ The fuel pressure should drop off no more than 10 psi from maximum pressure (no lower than 55 psi for a 65 psi max system or no lower than 45 psi for a 55 psi max system) within 5 minutes of the start of the test. ^ The fuel pressure should drop off to no less than 30 psi within 30 minutes of the start of the test. ^ For greatest accuracy, the service technician should read the fuel pressure as soon as possible after pump shut off, no more than 5 minutes after the start of the test. NOTE RETURNABLE AND ELECTRONIC RETURN LESS SYSTEMS SHOULD ALSO BE DIAGNOSED USING THE PROCEDURES LISTED FOR THEM IN PINPOINT TEST HC. IAC Diagnostic Service Tips - High Idle RPM at Start Up: ^ Most engines will have a temporary high idle at engine start up to allow for catalyst light off. If DTC 1506 is not present, this indicates that there is no fault present with the IAC. ^ A vehicle with very low odometer miles, may exhibit a higher than normal temporary startup fast idle (1600-2500 RPM that decreases slowly). No Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4230 repairs should be attempted because this is a normal temporary PCM calibration strategy to prevent spark plug fouling during plant/transportation operation. The calibration will permanently revert to its normal strategy after the PCM has seen its first 4 miles of continuous drive cycle. A brand new vehicle may accumulate some mileage without turning this strategy off if the drive cycle has been below 4 miles at a time. IAC Diagnostic Service Tips - EAC Valve Noise Issues For IAC valve noise concerns check for obstructed or potentially damaged IAC valve from backfire. NOTE Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4231 ON SOME NEWER MODEL YEAR VEHICLES THE REACTION SPEED OF THE EAC VALVE IS FAST ENOUGH THAT IT MIGHT MAKE A "POPPING" SOUND AS IT REACTS TO A LARGE IDLE LOAD. THIS IS A NORMAL CHARACTERISTIC AND NO ATTEMPTS SHOULD BE MADE IN AN EFFORT TO MODIFY THE PERFORMANCE OF THE IAC VALVE. IF POSSIBLE, COMPARE AGAINST A LIKE VEHICLE. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/-1 in.Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE, WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Cap: Customer Interest Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4240 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4241 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4242 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4243 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4244 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Cap: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4250 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4251 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4252 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4253 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4254 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Page 4255 Fuel Filler Cap: Description and Operation Fuel Filler Cap Fuel Filler Cap The fuel filler cap (Figure 100) is used to prevent fuel spill and close the evaporative emission/fuel system to atmosphere. Some vehicles may have a Fuel Cap Off Indicator Lamp (FCIL) in the instrument cluster which will illuminate when there is a failure in the vapor management system that may be due to the fuel filler cap not being sealed. Refer to the individual component for information on the following Evaporative Emission System components: fuel vapor control valve, fuel vapor vent valve assembly and fuel vapor separator assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 4260 Fuel Pressure Release: Service and Repair Fuel Pressure Gauge SPECIAL TOOL(S) WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Disconnect the battery ground cable. 2. Remove the Schrader valve cap and attach the Fuel Pressure Gauge. 3. Open the manual valve on the Fuel Pressure Gauge slowly to relieve the fuel system pressure. This may drain fuel from the system. Drain the fuel into a suitable container. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 4261 Fuel Pressure Gauge Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service and Repair Fuel Injector Wiring Harness: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Disconnect the six fuel injector electrical connectors. NOTE: One connector is shown, the other five are similar. 3. Remove the bolt. 4. Disconnect the ignition coil electrical connector. 5. Disconnect the radio interference capacitor electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service and Repair > Page 4266 6. Disconnect the engine coolant temperature sensor electrical connector and the water temperature indicator sender unit connector. 7. Disconnect the differential pressure feedback transducer electrical connector and the Camshaft Position (CMP) sensor electrical connector. 8. Remove the drive belt tensioner. 9. Disconnect the generator wiring and position the wiring aside. 10. Remove the generator mounting bracket. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service and Repair > Page 4267 11. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 12. Remove the wiring anchors and position the wiring aside. 13. Raise and support the vehicle. 14. On all models, disconnect the transmission portion of the wiring harness. 1 Disconnect the RH and LH Heated Oxygen Sensor (HO2S) connectors. 2 Disconnect the transmission control connector. 3 Disconnect the Output Shaft Speed (OSS) sensor connector. 4 Disconnect the digital Transmission Range (TR) sensor connector. 15. Disconnect the catalyst monitor sensor electrical connector. 16. Release the transmission/transfer case portion of the wiring harness from any routing clips or pushpins. 17. Route the transmission/transfer case portion of the wiring harness to the top of the engine. 18. Lower the vehicle. 19. Remove the wiring harness from the vehicle. INSTALLATION Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service and Repair > Page 4268 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service Precautions > Technician Safety Information Fuel Line Coupler: Technician Safety Information WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. ^ THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service Precautions > Technician Safety Information > Page 4273 Fuel Line Coupler: Vehicle Damage Warnings CAUTION: Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Push Connect Fittings Fuel Line Coupler: Service and Repair Push Connect Fittings Disconnect Tool, Spring Lock Coupling SPECIAL TOOL(S) DISCONNECT WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Relieve the fuel pressure. 2. Disconnect the safety clip from the male hose. 3. Install the Spring Lock Coupling Disconnect Tool and push it into the fitting. 4. Separate the fittings. ^ Inspect for damage. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Push Connect Fittings > Page 4276 ^ Clean the fittings. CONNECT 1. Align the tube to the fitting and push until you hear a click. 2. Pull on the fitting to make sure it is fully engaged, then install the safety clip. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Push Connect Fittings > Page 4277 Fuel Line Coupler: Service and Repair R-Clip Fittings DISCONNECT WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. CAUTION: Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks. 1. Relieve the fuel pressure. 2. Remove the shipping tab by bending downward. 3. Spread the R-clip legs and push the clip into the fitting. 4. Separate the fitting from the tube. CONNECT 1. Inspect the fitting and the tube for damage. Remove any dirt or obstructions. 2. Apply a light coat of Super Premium SAE 5W-30 XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G to the male tube end. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Push Connect Fittings > Page 4278 3. Insert the R-clip into the fitting. 4. Align the tube and the fitting. 5. Insert the tube into the fitting and push together until a click is heard. 6. Pull on the connection to make sure it is fully engaged. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Push Connect Fittings > Page 4279 Fuel Line Coupler: Service and Repair Spring Lock Couplings Special Tool(s) SPECIAL TOOL(S) DISCONNECT WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Relieve the fuel pressure. 2. Remove the safety clip. 3. Install the Spring Lock Coupling Disconnect Tool. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Push Connect Fittings > Page 4280 4. Close and push the Spring Lock Coupling Disconnect Tool into the open side of the cage. 5. Separate the coupler. 6. Remove the Spring Lock Coupling Disconnect Tool. CONNECT 1. Inspect and clean both the coupling ends. Lubricate the O-ring seals with Super Premium SAE 5W-30 XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Push Connect Fittings > Page 4281 2. Connect the coupler by inserting the male end into the female end of the coupler. Push the coupler together until the garter spring is engaged. 3. Pull on the coupler to make sure it is fully engaged. 4. Install the safety clip. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Push Connect Fittings > Page 4282 Fuel Line Coupler: Service and Repair Vapor Tube Fittings DISCONNECT 1. Disconnect the battery ground cable. WARNING: THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. 2. Disconnect the vapor tube from the fitting. 1 Squeeze the fitting. 2 Disconnect the vapor tube from the fitting. CONNECT 1. Inspect the fitting and the tube for damage. 2. Remove any dirt or obstructions. 3. Push the tube into the fitting until it snaps in place. 4. Pull on the connection to make sure the fitting is secure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Page 4283 Fuel Line Coupler: Tools and Equipment Special Tool(s) Disconnect Tool, Spring Lock Coupling Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation Fuel Pressure Regulator: Description and Operation Fuel Pressure Regulator Fuel Pressure Regulator The fuel pressure regulator (Figure 70) is attached to the fuel rail downstream of the fuel injectors. It regulates fuel pressure supplied to the fuel injectors. The regulator is a diaphragm-operated relief valve. One side of the diaphragm senses fuel pressure and the other side is connected to the intake manifold vacuum. Fuel pressure is established by a spring preload applied to the diaphragm. Balancing one side of the diaphragm with manifold vacuum maintains a constant fuel pressure drop across the fuel injectors. Fuel pressure is high when engine vacuum is low. Excess fuel is bypassed through the fuel pressure regulator and returned through the fuel return line to the fuel tank. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations View 151-15 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 4290 Connector View C435 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 4291 Fuel Pressure Sensor/Switch: Description and Operation Fuel Rail Pressure Sensor Fuel Rail Pressure (FRP) Sensor The Fuel Rail Pressure (FRP) sensor (Figure 30) is a diaphragm strain gauge device in which resistance changes with pressure. The electrical resistance of a strain gauge increases as pressure increases, and decreases as pressure decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to pressure. Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. Fuel Rail Pressure (FRP) Sensor The fuel rail pressure (FRP) sensor (Figure 31) senses the pressure difference between the fuel rail and the intake manifold. The return fuel line to the fuel tank has been deleted in this type of fuel system. The differential fuel/intake manifold pressure together with measured fuel temperature provides an indication of the fuel vapors in the fuel rail. Both differential pressure and temperature feedback signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserve fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Service Precautions > Technician Safety Information Fuel Pressure Test Port: Technician Safety Information WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Service Precautions > Technician Safety Information > Page 4296 Fuel Pressure Test Port: Vehicle Damage Warnings CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Service Precautions > Page 4297 Fuel Pressure Test Port: Description and Operation Pressure Test Point There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. ON VEHICLES NOT EQUIPPED WITH A SCHRADER VALVE, USE ROTUNDA FUEL PRESSURE TEST KIT #134-R0087 OR EQUIVALENT. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Service Precautions > Page 4298 Fuel Pressure Test Port: Service and Repair REMOVAL WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Remove the fuel injection supply manifold. 2. Remove the two bolts, the pressure relief valve and the O-ring seals. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. NOTE: Lubricate the new O-ring seals with clean engine oil to aid installation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper > Component Information > Service Precautions > Technician Safety Information Fuel Pressure Pulsation Damper: Technician Safety Information WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper > Component Information > Service Precautions > Technician Safety Information > Page 4303 Fuel Pressure Pulsation Damper: Vehicle Damage Warnings CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper > Component Information > Service Precautions > Page 4304 Fuel Pressure Pulsation Damper: Description and Operation Fuel Rail Pulse Damper Pulse Damper The fuel rail pulse damper (Figure 71) located on the fuel rail reduces fuel system noise caused by the pulsing of the fuel injectors. The vacuum port located on the damper is connected to manifold vacuum to avoid fuel spillage in the event the pulse damper diaphragm were to rupture. (The pulse damper should not be confused with a fuel pressure regulator, it does not regulate fuel rail pressure.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper > Component Information > Service Precautions > Page 4305 Fuel Pressure Pulsation Damper: Service and Repair REMOVAL WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Remove the fuel injection supply manifold. 2. Remove the two bolts, the fuel pulse damper and the O-ring seals. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. NOTE: Lubricate the new O-ring seals with clean engine oil to aid installation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Technician Safety Information Fuel Pressure Test Port: Technician Safety Information WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Technician Safety Information > Page 4312 Fuel Pressure Test Port: Vehicle Damage Warnings CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 4313 Fuel Pressure Test Port: Description and Operation Pressure Test Point There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. ON VEHICLES NOT EQUIPPED WITH A SCHRADER VALVE, USE ROTUNDA FUEL PRESSURE TEST KIT #134-R0087 OR EQUIVALENT. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 4314 Fuel Pressure Test Port: Service and Repair REMOVAL WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Remove the fuel injection supply manifold. 2. Remove the two bolts, the pressure relief valve and the O-ring seals. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. NOTE: Lubricate the new O-ring seals with clean engine oil to aid installation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Control Unit > Component Information > Description and Operation Fuel Pump Control Unit: Description and Operation Fuel Pump Driver Module Applications Fuel Pump Driver Module Duty Cycle Signals The Fuel Pump Driver Module (FPDM) communicates diagnostic information to the powertrain control module (PCM) through the Fuel Pump Monitor (FPM) circuit. This information is sent by the FPDM as a duty cycle signal. The three duty cycle signals that may be sent are listed in the table. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 4321 Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 4322 Connector View C1051 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 4323 Fuel Pump Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 4324 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service Precautions > Technician Safety Information Fuel Rail: Technician Safety Information WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service Precautions > Technician Safety Information > Page 4329 Fuel Rail: Vehicle Damage Warnings CAUTION: ^ If the supply manifold is used as a leverage device, damage may occur to the supply manifold. Care must be taken when working around the supply manifold. ^ Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service Precautions > Page 4330 Fuel Rail: Service and Repair REMOVAL WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. CAUTION: If the supply manifold is used as a leverage device, damage may occur to the supply manifold. Care must be taken when working around the supply manifold. 1. Remove the intake manifold. 2. Disconnect the fuel line. 3. Disconnect the six fuel injector electrical connectors. NOTE: One connector is shown, the other five are similar. 4. Remove the four bolts from the fuel line. 5. Disconnect the fuel pulse damper vacuum hose. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service Precautions > Page 4331 6. Remove the fuel injection supply manifold. 7. Remove the fuel injectors. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. NOTE: ^ Lubricate the new O-ring seals with clean engine oil. ^ Use new fasteners to attach the fuel line. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Tools and Equipment Fuel Supply Line: Tools and Equipment 3/8" Fuel Line Remover AST tool# 8013 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Tools and Equipment > Page 4335 Used for removing 3/8" fuel lines and feed lines from the fuel pump-sending unit. - For R and R of Fuel and Feed Lines - Quick line removal - Gold-Anodized Aluminum Construction - See Application Chart - Included in the 8100, 8107 and #8110 Line Disconnect Sets. Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 This Tool is also available in the following kits: 8110 - 10-Pc. Line Disconnect Set Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Tools and Equipment > Page 4336 8107 - 7-Piece Line Disconnect Set Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Hose: Customer Interest Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4346 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4347 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4348 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4349 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4350 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Hose: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4356 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4357 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4358 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4359 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4360 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Page 4361 Fuel Filler Hose: Service Precautions WARNING: DO NOT SMOKE, CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Vehicles Built After 03/2002 Fuel Filler Hose: Service and Repair Vehicles Built After 03/2002 REMOVAL WARNING: DO NOT SMOKE, CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. 1. Remove the fuel tank filler cap. NOTE: Fuel tank filler pipe may contain fuel. 2. Remove the screws. 3. Remove the fuel tank filler pipe from the fuel tank. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Vehicles Built After 03/2002 > Page 4364 Fuel Filler Hose: Service and Repair Vehicles Built Before 03/2002 REMOVAL 1. Remove the fuel tank filler cap. NOTE: Fuel tank filler pipe may contain fuel. 2. Remove the screws. 3. Remove the fuel tank filler pipe and the vent hose from the fuel tank and remove the fuel tank filler pipe. INSTALLATION 1. Install the fuel tank filler pipe and the vent hose. 1 Orient the clamp bonding patch with the top of the fuel tank. 2 Tighten the hose clamps. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Vehicles Built After 03/2002 > Page 4365 2. Install the three fuel tank filler pipe screws. 3. Install the fuel tank filler cap. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Neck: Customer Interest Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4374 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4375 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4376 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4377 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4378 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-20-3 > Oct > 03 > Emissions MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Neck: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-20-3 > Oct > 03 > Emissions MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4384 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-20-3 > Oct > 03 > Emissions MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4385 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-20-3 > Oct > 03 > Emissions MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4386 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-20-3 > Oct > 03 > Emissions MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4387 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-20-3 > Oct > 03 > Emissions MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4388 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Filler Neck: > 04-25-11 > Dec > 04 > A/C - Moaning From Engine Compartment Hose/Line HVAC: All Technical Service Bulletins A/C - Moaning From Engine Compartment TSB 04-25-11 12/27/04 MOAN/VIBRATION DURING A/C OPERATION FORD: 2001-2005 Explorer Sport Trac ISSUE Some 2001-2005 Explorer Sport Trac vehicles may exhibit a moan/vibration coming from the engine compartment while the A/C is on and the engine is at low RPM. The noise will only occur when the A/C compressor is running. ACTION Replace the manifold and tube assembly on the A/C compressor. Refer to Workshop Manual Section 412-03. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042511A Replace The Manifold And 1.7 Hrs. Tube Assembly On The A/C Compressor (Includes Time To Recover, Evacuate And Charge The Air Conditioning System) DEALER CODING CONDITION BASIC PART NO. CODE 19D734 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Service and Repair > Vehicles Built After 03/2002 Fuel Tank Mounting Straps: Service and Repair Vehicles Built After 03/2002 REMOVAL All vehicles 1. Raise and support the vehicle. 4x4 vehicles 2. Remove the fuel tank skid plate bolts. 3. Remove the fuel tank skid plate rear LH bolt. 4. Remove the fuel tank skid plate rear RH bolt and lower the fuel tank skid plate. All vehicles Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Service and Repair > Vehicles Built After 03/2002 > Page 4403 5. Use a suitable jack to support the fuel tank. 6. Remove the bolt and the fuel tank support strap. 7. Remove the bolt and the support strap. 8. Remove the bolt and the support strap. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Service and Repair > Vehicles Built After 03/2002 > Page 4404 Fuel Tank Mounting Straps: Service and Repair Vehicles Built Before 03/2002 REMOVAL All vehicles 1. Raise and support the vehicle. 4WD vehicles 2. Remove the fuel tank skid plate bolts. 3. Remove the fuel tank skid plate rear LH bolt. 4. Remove the fuel tank skid plate rear RH bolt and lower the fuel tank skid plate. All vehicles Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Service and Repair > Vehicles Built After 03/2002 > Page 4405 5. Use a suitable jack to support the fuel tank. 6. Remove the bolt and the fuel tank support strap. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams Fuel Tank Unit: Diagrams Connector View C433 Connector View C4033 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams > Page 4409 Fuel Tank Unit: Description and Operation Fuel Pump Module Fuel Pump Module Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams > Page 4410 Mechanical Returnless Fuel Pump Module (FPM) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams > Page 4411 Electronic Returnless Fuel Pump Module (FPM) The fuel pump (FP) module (Figure 66), (Figure 67) and (Figure 68) is a device that contains the fuel pump and sender assembly. The fuel pump is located inside the FP module reservoir and supplies fuel through the FP module manifold to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and a check valve located in the manifold outlet maintains system pressure when the fuel pump is not energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir and prime the fuel pump during the initial fill. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and Operation Fuel Temperature Sensor: Description and Operation Engine Fuel Temperature Sensor Engine Fuel Temperature (EFT) Sensor The Engine Fuel Temperature (EFT) sensor (Figure 28) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The EFT sensor measures the temperature of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams Connector View C1066 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Page 4418 Idle Air Control Valve: Description and Operation Idle Air Control Valve Nippondenso Idle Air Control (IAC) Valve Assembly Hitachi Idle Air Control (IAC) Valve Assembly With Vent/Filter The idle air control (IAC) valve assembly (Figure 117) and (Figure 118) controls engine idle speed and provides a dash pot function. The IAC valve assembly meters intake air around the throttle plate through a bypass within the IAC valve assembly and throttle body. The PCM determines the desired idle speed or bypass air and signals the IAC valve assembly through a specified duty cycle. The IAC valve responds by positioning the IAC valve to control the amount of bypassed air. The PCM monitors engine rpm and increases or decreases the IAC duty cycle in order to achieve the desired rpm. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Page 4419 Hitachi Idle Air Control (IAC) Valve Assembly With Air-Assist Injectors On applications with air-assisted injectors, the AC valve (Figure 119) also supplies a small amount of air into the path of the fuel injectors. The jet of air causes an increase in fuel atomization at low speed and light load conditions. NOTE: The IAC Valve Assembly is NOT ADJUSTABLE and CANNOT BE CLEANED. The IAC valve (part of throttle body assembly) has an internal diode on some applications. If the internal diode is measured in crossed terminal position with a digital multimeter, there will be an incorrect or negative reading. It is important that the mating component and harness connectors correctly oriented. Diagnostic procedures emphasize this importance. The PCM uses the IAC valve assembly to control: ^ No touch start ^ Cold engine fast idle for rapid warm-up ^ Idle (corrects for engine load) ^ Stumble or stalling on deceleration (provides a dash pot function) ^ Over-temperature idle boost. ^ Air Assist to Injectors. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Diagrams > Page 4420 Idle Air Control Valve: Service and Repair REMOVAL 1. Remove the accelerator control snow shield. 2. Disconnect the electrical connector, and remove the bolts and the Idle Air Control (IAC) valve. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations View 151-11 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 4424 Connector View C282 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 4425 Inertia Fuel Shutoff Switch: Description and Operation Inertia Fuel Shutoff (IFS) Switch The Inertia Fuel Shutoff (IFS) switch (Figure 72) is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shut off the fuel pump if a collision occurs. It consists of a steel ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and shuts off the electric fuel pump. Once the switch is open, it must be manually reset before restarting the vehicle. Refer to the Owner Guide for the location of the IFS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 4426 Inertia Fuel Shutoff Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Access the Inertia Fuel Shutoff (IFS) switch on the RH A-pillar lower trim panel and disconnect the electrical connector. 3. Remove the bolts and remove the IFS switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component Information > Service and Repair Intake Air Duct: Service and Repair REMOVAL 1. Remove the engine appearance cover bolts. 2. Remove the air cleaner outlet tube. 1 Unclip the wire harness. 2 Disconnect the crankcase ventilation tube. 3 Loosen the air cleaner outlet tube clamps and remove the air cleaner outlet tube. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Powertrain Control Module Power Relay: Locations Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4433 Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4434 Connector View C1016 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4435 Powertrain Control Module Power Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4436 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Description and Operation Fuel Pump Control Unit: Description and Operation Fuel Pump Driver Module Applications Fuel Pump Driver Module Duty Cycle Signals The Fuel Pump Driver Module (FPDM) communicates diagnostic information to the powertrain control module (PCM) through the Fuel Pump Monitor (FPM) circuit. This information is sent by the FPDM as a duty cycle signal. The three duty cycle signals that may be sent are listed in the table. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 4444 Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 4445 Connector View C1051 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 4446 Fuel Pump Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 4447 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Powertrain Control Module Power Relay: Locations Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4451 Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4452 Connector View C1016 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4453 Powertrain Control Module Power Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4454 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations View 151-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 4459 Connector View C128 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 4460 Mass Air Flow Sensor: Service Precautions CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 4461 Mass Air Flow Sensor: Description and Operation Mass Air Flow Sensor Typical Mass Air Flow (MAF) Sensor Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire Terminals The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 35). If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio (Figure 36). This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 4462 Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated intake air temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar, Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 4463 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Loosen the air cleaner outlet tube clamp and position the tube aside. 3. Remove the four bolts and the MAF sensor. CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations View 151-15 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 4467 Connector View C435 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 4468 Fuel Pressure Sensor/Switch: Description and Operation Fuel Rail Pressure Sensor Fuel Rail Pressure (FRP) Sensor The Fuel Rail Pressure (FRP) sensor (Figure 30) is a diaphragm strain gauge device in which resistance changes with pressure. The electrical resistance of a strain gauge increases as pressure increases, and decreases as pressure decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to pressure. Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. Fuel Rail Pressure (FRP) Sensor The fuel rail pressure (FRP) sensor (Figure 31) senses the pressure difference between the fuel rail and the intake manifold. The return fuel line to the fuel tank has been deleted in this type of fuel system. The differential fuel/intake manifold pressure together with measured fuel temperature provides an indication of the fuel vapors in the fuel rail. Both differential pressure and temperature feedback signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserve fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and Operation Fuel Temperature Sensor: Description and Operation Engine Fuel Temperature Sensor Engine Fuel Temperature (EFT) Sensor The Engine Fuel Temperature (EFT) sensor (Figure 28) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The EFT sensor measures the temperature of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations View 151-11 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 4475 Connector View C282 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 4476 Inertia Fuel Shutoff Switch: Description and Operation Inertia Fuel Shutoff (IFS) Switch The Inertia Fuel Shutoff (IFS) switch (Figure 72) is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shut off the fuel pump if a collision occurs. It consists of a steel ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and shuts off the electric fuel pump. Once the switch is open, it must be manually reset before restarting the vehicle. Refer to the Owner Guide for the location of the IFS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 4477 Inertia Fuel Shutoff Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Access the Inertia Fuel Shutoff (IFS) switch on the RH A-pillar lower trim panel and disconnect the electrical connector. 3. Remove the bolts and remove the IFS switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations View 151-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 4481 Connector View C189 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 4482 Throttle Position Sensor: Description and Operation Throttle Position Sensor Typical Throttle Position (TP) Sensor The throttle position (TP) sensor (Figure 41) is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is monitored by the OBD II system for component integrity, system functionality, and faults that can cause emissions levels to exceed standards set in government regulations. For additional information on the TP sensor, refer to Electronic EC System Hardware-PCM Inputs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 4483 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove the accelerator control snow shield. 2. Remove the Throttle Position (TP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolts and the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service Precautions > Technician Safety Information Throttle Body: Technician Safety Information WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service Precautions > Technician Safety Information > Page 4488 Throttle Body: Vehicle Damage Warnings CAUTION: Throttle body bore and plate area have a special coating and cannot be cleaned, or possible damage to the throttle body may occur. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service Precautions > Page 4489 Throttle Body: Description and Operation Throttle Body System Overview The throttle body system meters air to the engine during idle, part throttle, and Wide Open Throttle (WOT) conditions. The throttle body system consists of an Idle Air Control (IAC) valve assembly, idle air orifice, single or dual bores with butterfly valve throttle plates and a Throttle Position (TP) sensor. One other source of idle air flow is the Positive Crankcase Ventilation (PCV) system. The combined idle air flow (from idle air orifice IAC flow and PCV flow) is measured by the MAF sensor on all applications. During idle, the throttle body assembly provides a set amount of air flow to the engine through the idle air passage and PCV valve. The IAC valve assembly provides additional air when commanded by the powertrain control module (PCM) to maintain the proper engine idle speed under varying conditions. The IAC valve assembly mounts directly to the throttle body assembly in most applications, but is remote-mounted to the intake manifold in some applications. Idle speed is controlled by the PCM and cannot be adjusted. NOTE: The traditional idle air adjust procedure as well as throttle return screw are no longer used on On-Board Diagnostic (OBD) II applications. Throttle rotation is controlled by a cam/cable linkage to slow the initial opening rate of the throttle plate. The TP sensor monitors throttle position and provides an electrical signal to the PCM. Some throttle body applications provide an air supply channel upstream of the throttle plate to provide fresh air to the Positive Crankcase Ventilation (PCV) or AC Systems. Other throttle body applications provide individual vacuum taps downstream of the throttle plate for PCV return, Exhaust Gas Recirculation (EGR), Evaporative Emission (EVAP), and miscellaneous control signals. Throttle Body System Hardware The major components of the throttle body assembly include the TP sensor, IAC valve assembly, and throttle body housing assembly. Throttle Body Housing The throttle body housing assembly is a single piece of aluminum casting with an air passage and a butterfly throttle plate with linkage mechanisms. When the throttle plate is in the idle (or closed) position, the throttle lever arm should be in contact with the Throttle Return Stop. The throttle return stop prevents the throttle plate from contacting the bore and sticking closed. The setting also establishes the amount of air flow between the throttle plate and bore. To minimize the closed plate air flow, a special coating is applied to the throttle plate and bore to help seal this area. This sealant/coating also makes the throttle body resistant to engine intake sludge accumulation. Features of the Throttle Body Assembly include: 1. Idle air control (IAC) valve assembly mounted directly to the throttle body assembly (some vehicles). 2. A pre-set stop to locate the WOT position. 3. An air supply channel upstream of the throttle plate to provide fresh air to the PCV system (some vehicles only). 4. Individual vacuum taps for PCV, EGR, EVAP and miscellaneous control signals (some vehicles only). 5. PCV air return (if applicable). 6. A throttle body-mounted throttle position (TP) sensor. Typical Attention Decal Locations 7. A sealant/coating on the throttle bore and throttle plate makes the throttle body air flow tolerant to engine intake sludge accumulation. These throttle body assemblies MUST NOT BE CLEANED and have a white/black attention decal (Figure 116) advising not to clean. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service Precautions > Page 4490 Throttle Body: Service and Repair REMOVAL WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. CAUTION: Throttle body bore and plate area have a special coating and cannot be cleaned, or possible damage to the throttle body may occur. 1. Remove the air cleaner outlet tube. 2. Disconnect the Throttle Position (TP) sensor electrical connector. 3. Disconnect the accelerator cable and the speed control cable (if equipped). 4. Remove the throttle body. ^ Discard the gasket. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > Customer Interest for Throttle Cable/Linkage: > 05-10-3 > May > 05 > Interior - Accelerator Pedal Vibration at 1500-1800 RPM Throttle Cable/Linkage: Customer Interest Interior - Accelerator Pedal Vibration at 1500-1800 RPM TSB 05-10-3 05/30/05 ACCELERATOR PEDAL VIBRATION/BUZZ AT 1500-1800 RPM FORD: 2001-2005 Explorer Sport Trac ISSUE Some 2001-2005 Explorer Sport Trac vehicles may exhibit the accelerator pedal vibrating or buzzing at 1500-1800 RPM. ACTION Ensure the accelerator cable and the hood release cables are not contacting the # 6 spark plug wire. Reposition cables as needed. Also, ensure that the accelerator cable is secure in the retention clip, and that the clip's spring tensioner is on top. Refer to Figure 1 (incorrect position) and Figure 2 (correct position). WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9A758 43 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > Customer Interest for Throttle Cable/Linkage: > 05-10-3 > May > 05 > Interior - Accelerator Pedal Vibration at 1500-1800 RPM > Page 4499 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Cable/Linkage: > 05-10-3 > May > 05 > Interior - Accelerator Pedal Vibration at 1500-1800 RPM Throttle Cable/Linkage: All Technical Service Bulletins Interior - Accelerator Pedal Vibration at 1500-1800 RPM TSB 05-10-3 05/30/05 ACCELERATOR PEDAL VIBRATION/BUZZ AT 1500-1800 RPM FORD: 2001-2005 Explorer Sport Trac ISSUE Some 2001-2005 Explorer Sport Trac vehicles may exhibit the accelerator pedal vibrating or buzzing at 1500-1800 RPM. ACTION Ensure the accelerator cable and the hood release cables are not contacting the # 6 spark plug wire. Reposition cables as needed. Also, ensure that the accelerator cable is secure in the retention clip, and that the clip's spring tensioner is on top. Refer to Figure 1 (incorrect position) and Figure 2 (correct position). WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9A758 43 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Cable/Linkage: > 05-10-3 > May > 05 > Interior - Accelerator Pedal Vibration at 1500-1800 RPM > Page 4505 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > Page 4506 Torque Specifications Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > Page 4507 Throttle Cable/Linkage: Description and Operation The throttle is controlled by an accelerator cable attached to the accelerator pedal and shaft assembly. The accelerator pedal and shaft should travel smoothly from the idle position to the wide open throttle position. Hesitation or binding should not be experienced at any portion of the accelerator pedal and shaft travel. Surrounding components such as wiring, hoses, sound insulator and floor carpet must not contact the sliding inner member of the accelerator cable or interfere with the accelerator pedal and shaft. The acceleration control consists of an accelerator pedal and cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > Page 4508 Throttle Cable/Linkage: Testing and Inspection For further information regarding the diagnosis of this component, please refer to Accelerator Pedal; Testing and Inspection. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Cable Throttle Cable/Linkage: Service and Repair Cable REMOVAL 1. Disconnect the cable from the accelerator pedal. 2. Collapse the clips at the dash panel and push the cable through the dash panel into the engine compartment. 3. Remove the bolts and the accelerator cable snow shield. 4. Disconnect the cable from the throttle body. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Cable > Page 4511 5. Remove the accelerator cable. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Cable > Page 4512 Throttle Cable/Linkage: Service and Repair Pedal REMOVAL 1. Disconnect the cable from the accelerator pedal 2. Remove the screw and the accelerator pedal. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations View 151-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 4516 Connector View C189 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 4517 Throttle Position Sensor: Description and Operation Throttle Position Sensor Typical Throttle Position (TP) Sensor The throttle position (TP) sensor (Figure 41) is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is monitored by the OBD II system for component integrity, system functionality, and faults that can cause emissions levels to exceed standards set in government regulations. For additional information on the TP sensor, refer to Electronic EC System Hardware-PCM Inputs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 4518 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove the accelerator control snow shield. 2. Remove the Throttle Position (TP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolts and the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > System Information > Description and Operation > Intake Manifold Runner Control Variable Induction System: Description and Operation Intake Manifold Runner Control Intake Manifold Runner Control (IMRC) Electric Actuated System Intake Manifold Runner Control (IMRC) - Electric Actuated The Intake Manifold Runner Control (IMRC) Electric Actuated system (Figure 105) consists of a remote mounted motorized actuator with an attaching cable for each housing on each bank. Some applications will use one cable for both banks. The cable or linkage attaches to the housing butterfly plate levers. The 2.0L (2V) Focus/Escort IMRC uses a motorized actuator mounted directly to a single housing without the use of a cable. Each IMRC housing is an aluminum casting with two intake air passages for each cylinder. One passage is always open and the other is opened and closed with a butterfly valve plate. The housing uses a return spring to hold the butterfly valve plates closed. The motorized actuator houses an internal switch or switches, depending on the application, to provide feedback to the PCM indicating cable and butterfly valve plate position. Below approximately 3000 rpm, the motorized actuator will not be energized. This will allow the cable to fully extend and the butterfly valve plates to remain closed. Above approximately 3000 rpm, the motorized actuator will be energized. The attaching cable will pull the butterfly valve plates into the open position. Some vehicles will activate the IMRC near 1500 rpm. WARNING: SUBSTANTIAL OPENING AND CLOSING TORQUE IS APPLIED BY THIS SYSTEM. TO PREVENT INJURY, BE CAREFUL TO KEEP FINGERS AWAY FROM LEVER MECHANISMS WHEN ACTUATED. 1. The PCM uses the Throttle Position (TP) sensor and Crankshaft Position (CKP) signals to determine activation of the IMRC system. There must be a positive change in voltage from the TP sensor along with the increase in rpm to open the valve plates. 2. The PCM uses the information from the input signals to control the IMRC motorized actuator based upon rpm and changes in throttle position. 3. The PCM energizes the actuator to pull the butterfly plates open with the cable(s) or linkage. 4. The IMRC housing contain butterfly plates to allow increased air flow. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > System Information > Description and Operation > Intake Manifold Runner Control > Page 4523 Variable Induction System: Description and Operation Intake Manifold Swirl Control Intake Manifold Swirl Control (IMSC) Vacuum Actuated System Intake Manifold Swirl Control (IMSC) - Vacuum Actuated The Intake Manifold Swirl Control (IMSC) Vacuum Actuated system (Figure 106) consists of a manifold mounted vacuum actuator and a PCM controlled electric solenoid. The linkage from the actuator attaches to the manifold butterfly plate lever. The IMSC actuator and manifold are composite/plastic with a single intake air passage for each cylinder. The passage has a butterfly valve plate that blocks 60% of the opening when actuated, leaving the top of the passage open to generate turbulence. The housing uses a return spring to hold the butterfly valve plates open. The vacuum actuator houses an internal monitor circuit to provide feedback to the PCM indicating butterfly valve plate position. Below approximately 3000 rpm, the vacuum solenoid will be energized. This will allow manifold vacuum to be applied and the butterfly valve plates to remain closed. Above approximately 3000 rpm, the vacuum solenoid will be de-energized. This will allow vacuum to vent from the actuator and the butterfly valve plates to open. WARNING: SUBSTANTIAL OPENING AND CLOSING TORQUE IS APPLIED BY THIS SYSTEM. TO PREVENT INJURY, BE CAREFUL TO KEEP FINGERS AWAY FROM LEVER MECHANISMS WHEN ACTUATED. 1. The PCM monitors the TP sensor, Cylinder Head Temperature (CHT) and Crankshaft Position (CKP) signals to determine activation of the IMSC system. There must be a positive change in voltage from the TP sensor along with the increase in rpm at the proper engine temperature to open the valve plates. 2. The PCM uses the information from the input signals to control the IMSC electric solenoid based upon changes in throttle position, engine temperature and rpm. 3. The PCM energizes the solenoid with the key on engine running, vacuum is then applied to the actuator to pull the butterfly plates closed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > System Information > Description and Operation > Intake Manifold Runner Control > Page 4524 Variable Induction System: Description and Operation Intake Manifold Tuning Valve Intake Manifold Tuning Valve (IMTV) Intake Manifold Tuning Valve (IMTV) The intake manifold tuning valve (IMTV) (Figure 107) is a motorized actuated unit mounted directly to the intake manifold. The IMTV actuator controls a shutter device attached to the actuator shaft. There is no monitor input to the PCM with this system to indicate shutter position. The motorized IMTV unit will not be energized below approximately 2600 rpm or higher on some vehicles. The shutter will be in the closed position not allowing airflow blend to occur in the intake manifold. Above approximately 2600 rpm or higher, the motorized unit will be energized. The motorized unit will be commanded on by the PCM initially at a 100 percent duty cycle to move the shutter to the open position and then falling to approximately 50 percent to continue to hold the shutter open. 1. The PCM uses the TP sensor and CKP signals to determine activation of the IMTV system. There must be a positive change in voltage from the TP sensor along with the increase in rpm to open the shutter. 2. The PCM uses the information from the input signals to control the IMTV. 3. When commanded on by the PCM, the motorized actuator shutter opens up the end of the vertical separating wall at high engine speeds to allow both sides of the manifold to blend together. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications Firing Order: Specifications Coil Terminal-To-Cylinder Relationship Firing order........................................................................................................................................... ..................................................................1-4-2-5-3-6 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Page 4529 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations View 151-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4537 Connector View C180 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > PCM Input Camshaft Position Sensor: Description and Operation PCM Input Camshaft Position Sensor The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No.1 is on its compression stroke. A signal is then sent to the powertrain control module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctance Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22) and the two pin connector variable reluctance sensor (Figure 23). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > PCM Input > Page 4540 Camshaft Position Sensor: Description and Operation Ignition Systems Camshaft Position Sensor Camshaft Position (CMP) Sensor The camshaft position sensor (Figure 55) used by COP Integrated EI system is a magnetic transducer mounted on the engine front cover adjacent to the camshaft. By monitoring a target on the camshaft sprocket, the CMP sensor identifies cylinder one to the PCM. The COP Integrated EI system uses this information to synchronize the firing of the individual coils. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 4541 Camshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations View 151-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4545 Connector View C101 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > PCM Input Crankshaft Position Sensor: Description and Operation PCM Input Crankshaft Position Sensor (Integrated Ignition Systems) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the powertrain control module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to fixed reference (Figure 25). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > PCM Input > Page 4548 Crankshaft Position Sensor: Description and Operation Ignition Systems Crankshaft Position Sensor Typical Crankshaft Position (CKP) Sensor The crankshaft position (CKP) sensor (Figure 54) is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP sensor is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to a fixed reference (Figure 54) for the CKP sensor configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between teeth. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Page 4549 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Crankshaft Position (CKP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ The new CKP sensor needs to be touching the damper. The new sensor has wear tabs that will wear off after several engine revolutions. ^ Be sure the sensor wiring is routed away from the battery cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 05-10-3 > May > 05 > Interior - Accelerator Pedal Vibration at 1500-1800 RPM Ignition Cable: Customer Interest Interior - Accelerator Pedal Vibration at 1500-1800 RPM TSB 05-10-3 05/30/05 ACCELERATOR PEDAL VIBRATION/BUZZ AT 1500-1800 RPM FORD: 2001-2005 Explorer Sport Trac ISSUE Some 2001-2005 Explorer Sport Trac vehicles may exhibit the accelerator pedal vibrating or buzzing at 1500-1800 RPM. ACTION Ensure the accelerator cable and the hood release cables are not contacting the # 6 spark plug wire. Reposition cables as needed. Also, ensure that the accelerator cable is secure in the retention clip, and that the clip's spring tensioner is on top. Refer to Figure 1 (incorrect position) and Figure 2 (correct position). WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9A758 43 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 05-10-3 > May > 05 > Interior - Accelerator Pedal Vibration at 1500-1800 RPM > Page 4558 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 05-10-3 > May > 05 > Interior - Accelerator Pedal Vibration at 1500-1800 RPM Ignition Cable: All Technical Service Bulletins Interior - Accelerator Pedal Vibration at 1500-1800 RPM TSB 05-10-3 05/30/05 ACCELERATOR PEDAL VIBRATION/BUZZ AT 1500-1800 RPM FORD: 2001-2005 Explorer Sport Trac ISSUE Some 2001-2005 Explorer Sport Trac vehicles may exhibit the accelerator pedal vibrating or buzzing at 1500-1800 RPM. ACTION Ensure the accelerator cable and the hood release cables are not contacting the # 6 spark plug wire. Reposition cables as needed. Also, ensure that the accelerator cable is secure in the retention clip, and that the clip's spring tensioner is on top. Refer to Figure 1 (incorrect position) and Figure 2 (correct position). WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9A758 43 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 05-10-3 > May > 05 > Interior - Accelerator Pedal Vibration at 1500-1800 RPM > Page 4564 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Page 4565 Ignition Cable: Service Precautions CAUTION: ^ Spark plug wires must be connected correctly. Mark the spark plug wires before removing them. ^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. ^ Be sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifold. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Page 4566 Ignition Cable: Service and Repair Spark Plug Wire Remover SPECIAL TOOL(S) REMOVAL 1. Remove the right front tire. 2. Remove the right front fenderwell splash shield. 3. With a twisting motion, use the special tool to pull the spark plug wires from the right side of the engine. CAUTION: ^ Spark plug wires must be connected correctly. Mark the spark plug wires before removing them. ^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. 4. Lower the vehicle. 5. With a twisting motion, use the special tool to pull the spark plug wires from the left side of the engine. CAUTION: ^ Spark plug wires must be connected correctly. Mark the spark plug wires before removing them. ^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Page 4567 6. Squeeze the locking tabs and twist while pulling upward to remove the spark plug wires from the ignition coil. 7. Disconnect the spark plug wires from the separators and remove the spark plug wires. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Be sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifold. NOTE: Apply silicone dielectric compound to the inside of the spark plug and ignition coil boots of the spark plug wire. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Page 4568 Spark Plug Wire Remover Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams Connector View C1065 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 4572 Ignition Coil: Service Precautions CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 4573 Ignition Coil: Description and Operation Coil Pack Horizontal Connector Six Tower Coil Pack Series 5 Six Tower Coil Pack Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 4574 Four - Tower Coil Packs Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 4575 Series 5 Four Tower Coil Pack Coil packs come in four tower, Series 5 four tower, six-tower horizontal connector and Series 5 Six tower models. Two adjacent coil towers share a common coil and are called a matched pair. For six-tower coil pack (six cylinder) applications the matched pairs are 1 and 5, 2 and 6, and 3 and 4 (Figure 56)and (Figure 57). For four-tower coil pack (four cylinder) applications the matched pairs are 1 and 4, and 2 and 3 (Figure 58) and (Figure 59). When the coil is fired by the PCM, spark is delivered through the matched pair towers to their respective spark plugs. The spark plugs are fired simultaneously and are paired so that as one fires on the compression stroke, the other spark plug fires on the exhaust stroke. The next time the coil is fired the situation is reversed. The next pair of spark plugs fire according to the engine firing order. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 4576 Ignition Coil: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the ignition coil electrical connector. 3. Squeeze the locking tabs and twist while pulling upward to disconnect the six spark plug wires. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug wire locations before removing them. 4. Remove the bolts and the ignition coil. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Apply silicone dielectric compound to the inside of the spark plug wire coil boots. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations View 151-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 4580 Connector View C109 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 4581 Knock Sensor: Description and Operation Knock Sensor Knock Sensor (KS) The knock Sensor (KS) (Figure 34) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 4582 Knock Sensor: Service and Repair REMOVAL 1. Disconnect the Knock Sensor (KS) electrical connector. 2. Remove the intake manifold. 3. Remove the KS. 1 Remove the bolt. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations View 151-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4587 Connector View C180 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > PCM Input Camshaft Position Sensor: Description and Operation PCM Input Camshaft Position Sensor The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No.1 is on its compression stroke. A signal is then sent to the powertrain control module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctance Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22) and the two pin connector variable reluctance sensor (Figure 23). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > PCM Input > Page 4590 Camshaft Position Sensor: Description and Operation Ignition Systems Camshaft Position Sensor Camshaft Position (CMP) Sensor The camshaft position sensor (Figure 55) used by COP Integrated EI system is a magnetic transducer mounted on the engine front cover adjacent to the camshaft. By monitoring a target on the camshaft sprocket, the CMP sensor identifies cylinder one to the PCM. The COP Integrated EI system uses this information to synchronize the firing of the individual coils. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 4591 Camshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations View 151-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4595 Connector View C101 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > PCM Input Crankshaft Position Sensor: Description and Operation PCM Input Crankshaft Position Sensor (Integrated Ignition Systems) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the powertrain control module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to fixed reference (Figure 25). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > PCM Input > Page 4598 Crankshaft Position Sensor: Description and Operation Ignition Systems Crankshaft Position Sensor Typical Crankshaft Position (CKP) Sensor The crankshaft position (CKP) sensor (Figure 54) is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP sensor is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to a fixed reference (Figure 54) for the CKP sensor configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid decelerations between teeth. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Page 4599 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Crankshaft Position (CKP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ The new CKP sensor needs to be touching the damper. The new sensor has wear tabs that will wear off after several engine revolutions. ^ Be sure the sensor wiring is routed away from the battery cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Specifications Ignition Switch Lock Cylinder: Specifications Lock Cylinder Housing Screws ............................................................................................................ .................................................... 22 Nm (16 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder-Functional Lock Cylinder Removal 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock cylinder. 3. To install, reverse the removal procedure. ^ Verify ignition switch lock cylinder operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 4606 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional Ignition Switch Lock Cylinder-Non-Functional Lock Cylinder Removal and Installation 1. NOTE: Make sure the front wheels are in the straight-ahead position. Disconnect the battery ground cable and wait at least one minute. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes and instructions in the steering wheel removal and installation procedure. Remove the steering wheel assembly. 3. Twist off the cap from the ignition switch cylinder. 4. NOTE: The lock cylinder is repaired by discarding the inoperative lock cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code oil the vehicle. Remove the ignition switch lock cylinder. ^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. ^ Use a 3/8-inch drill bit to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. ^ Remove and discard the ignition switch lock cylinder and clean the drill shavings from the steering column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 4607 5. Remove the bearing retainer. 6. Remove the bearing and gear. ^ Thoroughly clean all drill shavings from the steering column and inspect it for damage. 7. To install, reverse the removal procedure. ^ Install a new ignition switch lock cylinder. ^ Verify ignition switch lock cylinder operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations View 151-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 4611 Connector View C109 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 4612 Knock Sensor: Description and Operation Knock Sensor Knock Sensor (KS) The knock Sensor (KS) (Figure 34) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 4613 Knock Sensor: Service and Repair REMOVAL 1. Disconnect the Knock Sensor (KS) electrical connector. 2. Remove the intake manifold. 3. Remove the KS. 1 Remove the bolt. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Gap Spark Plug: Specifications Gap Item....................................................................................................................................................... ..............................................................Specification Spark plug gap..................................................................................................................................... ....................................1.57-1.73 mm (0.061-0.068 in) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Gap > Page 4618 Spark Plug: Specifications Torque Item....................................................................................................................................................... ..............................................................Specification Spark plug............................................................................................................................................ .........................................................17 Nm (13 Lb-Ft) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 4619 Spark Plug: Application and ID Item....................................................................................................................................................... ..............................................................Specification Spark plug type..................................................................................................................................... ..................................................................AGSF34FP Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 4620 Spark Plug: Service and Repair REMOVAL 1. Remove the spark plug wires from the spark plugs. 2. Remove the spark plugs. NOTE: ^ Use compressed air to remove any foreign material in the spark plug well before removing the spark plugs. ^ If an original spark plug is reused, make sure it is installed in the same cylinder it was taken from. New spark plugs can be used in any cylinder. 3. Inspect the spark plugs. 4. Use a suitable spark plug gap tool to check and adjust the spark plug gap. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations Pressure Regulating Solenoid: Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 4627 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 4628 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 4629 SSA, SSC solenoids 1. TCC solenoid 2. SSB, SSD solenoids 3. EPC solenoid Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Pressure Regulating Solenoid: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. NOTE: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4632 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number or the component name in one of the the A-Z Component Lists, the Component Location description for that component can easily be found. See: Locations/Component Locations/A-Z Component List Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4633 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4634 the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4635 that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4636 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4637 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4638 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4639 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4640 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4641 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4642 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4643 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4644 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4645 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4646 Systems Overview Wire Color Code Identification Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4647 OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4648 Pressure Regulating Solenoid: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4649 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4650 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4651 Pressure Regulating Solenoid: Exploded Views Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4652 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4653 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4654 Pressure Regulating Solenoid: Electrical Diagrams Diagram 29-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4655 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4656 Pressure Regulating Solenoid: Description and Operation Electronic Pressure Control (EPC) Solenoid The electronic pressure control (EPC) solenoid is a variable force style (VFS) solenoid. The VFS type solenoid is an electro-hydraulic actuator combining a solenoid and a regulating valve. The powertrain control module (PCM) varies the current to the EPC solenoid. This action causes the solenoid to regulate transmission line pressure and line modulator pressure. This is done by producing resisting forces to the main regulator and line modulator circuits. These two circuits control clutch application pressures. The PCM has an adaptive learn strategy to electronically control the transmission which will automatically adjust the shift feel. When the battery has been disconnected or a new battery installed, certain transmission operating parameters may be lost. The PCM must relearn these parameters. During this learning process you may experience slightly firm shifts, delayed, or early shifts. This operation is considered normal and will not affect the function of the transmission. Normal operation will return once these parameters are stored by the PCM. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4657 Pressure Regulating Solenoid: Service and Repair Solenoids-Shift, Torque Converter Clutch, Electronic Pressure Control Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal If equipped, loosen the nut and position the heat shield out of the way. 4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid. 6. Remove the transmission fluid filter. 1 Remove the transmission fluid filter screw. 2 Remove the transmission fluid filter. 7. NOTE: Main control assembly does not need to be removed for solenoid service. Remove wire loom guide and protector. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4658 8. Disconnect the appropriate solenoid electrical connector. 1 Disconnect shift solenoids electrical connectors. 2 Disconnect the Torque Converter Clutch (TCC) solenoid electrical connector. 3 Disconnect the Electronic Pressure Control (EPC) solenoid electrical connector. 9. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve. CAUTION: Shift Solenoid (SSC) may pop out of its bore. This may damage the solenoid. Remove the shift solenoids. 1 Remove the wire harness 2 Remove the solenoid clamp screws. 3 Remove the solenoid clamp 4 Remove the appropriate solenoid(s) Installation 1. Install the new solenoid(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4659 2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 2W plug. Install the solenoid clamp 1 Position the solenoid clamp on the main control valve body. 2 Install the solenoid clamp screws. 3. Connect the six solenoid electrical connectors. 1 Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2 Connect the Torque Converter Clutch (TCC) solenoid electrical connector. 3 Connect the Electrical Pressure Control (EPC) solenoid electrical connector. 4. CAUTION: Excessive pressure may break the retaining pins. Install the main control valve body wire loom. Align the retaining pins to the holes in the solenoid clamps and gently press in the main control valve body wire loom guide and protector. 5. Install the transmission fluid filter. 1 Install the transmission fluid filter. 2 Install the transmission fluid filter screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4660 6. Install the transmission fluid pan. 1 Position a new transmission fluid pan gasket on the transmission fluid pan. 2 Align and install the transmission fluid pan. - Loosely install the transmission fluid pan screws. 7. Tighten the transmission fluid pan screws. - Tighten the transmission fluid pan screws in a crisscross sequence. 8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle. 10. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. 11. Fill the transmission to the correct fluid level and check for correct transmission operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications Shift Interlock Solenoid: Specifications Bolts retaining the shift lock actuator to the transmission column shift selector tube ............................................................................. 9 Nm (80 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 4664 Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator Removal and Installation 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches.Please refer to the appropriate location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable. Wait at least one minute before proceeding with the procedure to allow the backup power supply to deplete its energy. 2. Remove the lower steering column opening finish panel. 1 Remove the screws and position the hood release handle out of the way. 2 Remove the two screws from the lower steering column opening finish panel. 3 Pull outward to release the retaining clips and remove the lower steering column opening finish panel. 3. Remove the five bolts and the lower steering column opening finish panel reinforcement. 4. Remove the four nuts and lower the steering column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 4665 5. Remove the three bolts and separate the insert plate and shift lock actuator from the steering column. 6. Disconnect the electrical connector and remove the insert plate and shift lock actuator. 7. NOTE: The shift lock actuator clip is an assembly aid for the assembly plant. It is not necessary to install a new clip for installation. Remove and discard the clip. 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications Shift Solenoid: Specifications Solenoid clamp screws ........................................................................................................................ ............................................ 6-8 Nm (53-71 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 4669 Shift Solenoid: Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 4670 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 4671 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 4672 SSA, SSC solenoids 1. TCC solenoid 2. SSB, SSD solenoids 3. EPC solenoid Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. NOTE: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4675 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number or the component name in one of the the A-Z Component Lists, the Component Location description for that component can easily be found. See: Locations/Component Locations/A-Z Component List Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4676 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4677 the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4678 that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4679 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4680 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4681 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4682 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4683 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4684 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4685 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4686 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4687 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4688 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4689 Systems Overview Wire Color Code Identification Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4690 OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4691 Shift Solenoid: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4692 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4693 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4694 Shift Solenoid: Exploded Views Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4695 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4696 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4697 Shift Solenoid: Electrical Diagrams Diagram 29-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4698 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4699 Shift Solenoid: Description and Operation Shift Solenoids A, B, C, and D Four On/Off shift solenoids allow the powertrain control module to control shift scheduling. - The solenoids are two-way, normally open style. - The shift solenoids (SSA, SSB, SSC, and SSD) provide gear selection by controlling the pressures of the shift valves. - SSD is also used to apply and release the coast clutch. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4700 Shift Solenoid: Service and Repair Solenoids-Shift, Torque Converter Clutch, Electronic Pressure Control Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal If equipped, loosen the nut and position the heat shield out of the way. 4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid. 6. Remove the transmission fluid filter. 1 Remove the transmission fluid filter screw. 2 Remove the transmission fluid filter. 7. NOTE: Main control assembly does not need to be removed for solenoid service. Remove wire loom guide and protector. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4701 8. Disconnect the appropriate solenoid electrical connector. 1 Disconnect shift solenoids electrical connectors. 2 Disconnect the Torque Converter Clutch (TCC) solenoid electrical connector. 3 Disconnect the Electronic Pressure Control (EPC) solenoid electrical connector. 9. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve. CAUTION: Shift Solenoid (SSC) may pop out of its bore. This may damage the solenoid. Remove the shift solenoids. 1 Remove the wire harness 2 Remove the solenoid clamp screws. 3 Remove the solenoid clamp 4 Remove the appropriate solenoid(s) Installation 1. Install the new solenoid(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4702 2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 2W plug. Install the solenoid clamp 1 Position the solenoid clamp on the main control valve body. 2 Install the solenoid clamp screws. 3. Connect the six solenoid electrical connectors. 1 Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2 Connect the Torque Converter Clutch (TCC) solenoid electrical connector. 3 Connect the Electrical Pressure Control (EPC) solenoid electrical connector. 4. CAUTION: Excessive pressure may break the retaining pins. Install the main control valve body wire loom. Align the retaining pins to the holes in the solenoid clamps and gently press in the main control valve body wire loom guide and protector. 5. Install the transmission fluid filter. 1 Install the transmission fluid filter. 2 Install the transmission fluid filter screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4703 6. Install the transmission fluid pan. 1 Position a new transmission fluid pan gasket on the transmission fluid pan. 2 Align and install the transmission fluid pan. - Loosely install the transmission fluid pan screws. 7. Tighten the transmission fluid pan screws. - Tighten the transmission fluid pan screws in a crisscross sequence. 8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle. 10. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. 11. Fill the transmission to the correct fluid level and check for correct transmission operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations Torque Converter Clutch Solenoid: Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 4707 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 4708 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 4709 SSA, SSC solenoids 1. TCC solenoid 2. SSB, SSD solenoids 3. EPC solenoid Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. NOTE: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4712 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number or the component name in one of the the A-Z Component Lists, the Component Location description for that component can easily be found. See: Locations/Component Locations/A-Z Component List Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4713 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4714 the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4715 that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4716 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4717 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4718 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4719 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4720 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4721 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4722 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4723 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4724 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4725 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4726 Systems Overview Wire Color Code Identification Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4727 OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4728 Torque Converter Clutch Solenoid: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4729 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4730 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4731 Torque Converter Clutch Solenoid: Exploded Views Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4732 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4733 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4734 Torque Converter Clutch Solenoid: Electrical Diagrams Diagram 29-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4735 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4736 Torque Converter Clutch Solenoid: Description and Operation Torque Converter Clutch (TCC) Solenoid The torque converter clutch (TCC) solenoid is used to control the apply and release of the TCC. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4737 Torque Converter Clutch Solenoid: Service and Repair Solenoids-Shift, Torque Converter Clutch, Electronic Pressure Control Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal If equipped, loosen the nut and position the heat shield out of the way. 4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid. 6. Remove the transmission fluid filter. 1 Remove the transmission fluid filter screw. 2 Remove the transmission fluid filter. 7. NOTE: Main control assembly does not need to be removed for solenoid service. Remove wire loom guide and protector. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4738 8. Disconnect the appropriate solenoid electrical connector. 1 Disconnect shift solenoids electrical connectors. 2 Disconnect the Torque Converter Clutch (TCC) solenoid electrical connector. 3 Disconnect the Electronic Pressure Control (EPC) solenoid electrical connector. 9. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve. CAUTION: Shift Solenoid (SSC) may pop out of its bore. This may damage the solenoid. Remove the shift solenoids. 1 Remove the wire harness 2 Remove the solenoid clamp screws. 3 Remove the solenoid clamp 4 Remove the appropriate solenoid(s) Installation 1. Install the new solenoid(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4739 2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 2W plug. Install the solenoid clamp 1 Position the solenoid clamp on the main control valve body. 2 Install the solenoid clamp screws. 3. Connect the six solenoid electrical connectors. 1 Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2 Connect the Torque Converter Clutch (TCC) solenoid electrical connector. 3 Connect the Electrical Pressure Control (EPC) solenoid electrical connector. 4. CAUTION: Excessive pressure may break the retaining pins. Install the main control valve body wire loom. Align the retaining pins to the holes in the solenoid clamps and gently press in the main control valve body wire loom guide and protector. 5. Install the transmission fluid filter. 1 Install the transmission fluid filter. 2 Install the transmission fluid filter screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4740 6. Install the transmission fluid pan. 1 Position a new transmission fluid pan gasket on the transmission fluid pan. 2 Align and install the transmission fluid pan. - Loosely install the transmission fluid pan screws. 7. Tighten the transmission fluid pan screws. - Tighten the transmission fluid pan screws in a crisscross sequence. 8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle. 10. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. 11. Fill the transmission to the correct fluid level and check for correct transmission operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams Connector View C167 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams Connector View C279 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > PCM Inputs Transmission Mode Switch: Description and Operation PCM Inputs TRANSMISSION CONTROL SWITCH Transmission Control Switch (TCS) Transmission Control Switch (TCS) The Transmission Control Switch (TCS) (Figures 43 and 44) signals the PCM with key power whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > PCM Inputs > Page 4751 Transmission Mode Switch: Description and Operation PCM Output Transmission Control Indicator Lamp The Transmission Control Indicator Lamp (TCIL) is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Refer to Transmission Control Switch in Hardware PCM Inputs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > Page 4752 Transmission Mode Switch: Service and Repair Transmission Control Switch Removal and Installation 1. Remove the Transmission Control Switch (TCS). 1 Remove the cover. 2 Remove the TCS. 2. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission Range (TR) sensor screws .......................................................................................................................... 8-11 Nm (71-97 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4756 View 151-5 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4757 Connector View C167 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4758 Digital Transmission Range Sensor: Description and Operation Digital Transmission Range (TR) Sensor The digital Transmission Range (TR) sensor is located on the outside of the transmission at the manual lever. The digital TR sensor completes the start circuit in PARK, NEUTRAL, and the back-up lamp circuit in REVERSE. The digital TR sensor also opens and closes a set of four switches that are monitored by the Powertrain Control Module (PCM) to determine the position of the manual lever (P, R, N, (D), 3, 2, 1). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4759 Digital Transmission Range Sensor: Service and Repair Digital Transmission Range (TR) Sensor Special Tools Special Tool(s) Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Disconnect the shift cable from the manual control lever. 4. Disconnect the digital Transmission Range (TR) sensor electrical connector. 5. Remove the manual control outer lever nut and manual control outer lever. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4760 6. Remove the screws and the digital TR sensor. Installation 1. Install the digital TR sensor and loosely install the screws. 2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence. 3. Install the manual control outer lever and nut. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4761 4. Connect the digital Transmission Range (TR) sensor electrical connector. 5. Connect the shift cable to the manual control lever. 6. Verify that the shift cable is adjusted. 7. Lower the vehicle. 8. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Turbine shaft speed (TSS) sensor screw ....................................................................................................................................... 8-11 Nm (71-97 inch lbs.) Output shaft speed sensor (OSS) sensor screw ............................................................................................................................. 8-11 Nm (71-97 inch lbs.) Intermediate shaft speed sensor (ISS) sensor ................................................................................................................................ 8-11 Nm (71-97 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor View 151-5 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 4767 Transmission Speed Sensor: Locations Output Shaft Speed Sensor View 151-5 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 4768 View 151-6 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Intermediate Shaft Speed Sensor Connector View C164 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Intermediate Shaft Speed Sensor > Page 4771 Transmission Speed Sensor: Diagrams Output Shaft Speed Sensor Connector View C193 Connector View C1107 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 4772 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED SENSOR The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Removal 1. Raise and support the vehicle. 2. Disconnect Output Shaft Speed (OSS) sensor electrical connector. 3. Remove OSS sensor. 1 Remove the OSS sensor screw. 2 Remove the OSS sensor from the transmission. - Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring. Installation 1. Inspect and lubricate O-ring with petroleum jelly. 1 Install the OSS sensor into the transmission. 2 Tighten OSS sensor screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor > Page 4775 2. Connect OSS sensor electrical connector. 3. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor > Page 4776 Transmission Speed Sensor: Service and Repair Intermediate Shaft Speed Sensor Intermediate Shaft Speed Sensor Removal 1. Raise and support the vehicle. 2. Disconnect Intermediate Shaft Speed (ISS) sensor electrical connector. 3. Remove ISS sensor. 1 Remove the ISS sensor screw. 2 Remove the ISS sensor from the transmission. - Inspect the ISS sensor O-ring for damage. If damaged, install a new O-ring. Installation 1. Inspect and lubricate O-ring with petroleum jelly. 1 Install the ISS sensor into the transmission. 2 Tighten ISS sensor screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor > Page 4777 2. Connect ISS sensor electrical connector. 3. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations The Transmission Fluid Temperature Sensor is located on the solenoid body. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Temperature Sensor/Switch: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. NOTE: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4783 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number or the component name in one of the the A-Z Component Lists, the Component Location description for that component can easily be found. See: Locations/Component Locations/A-Z Component List Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4784 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4785 the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4786 that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4787 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4788 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4789 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4790 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4791 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4792 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4793 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4794 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4795 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4796 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4797 Systems Overview Wire Color Code Identification Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4798 OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4799 Transmission Temperature Sensor/Switch: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4800 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4801 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4802 Transmission Temperature Sensor/Switch: Electrical Diagrams Diagram 29-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4803 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Page 4804 Transmission Temperature Sensor/Switch: Description and Operation Transmission Fluid Temperature (TFT) Sensor The transmission fluid temperature (TFT) sensor is a thermistor-type sensor that varies a reference voltage signal. The resistance in the TFT varies with temperature. The powertrain control module (PCM) monitors the voltage signal across the TFT, and uses this information to determine the transmission fluid temperature. The TFT is located on the main control body wiring harness assembly. The PCM uses the TFT signal to help determine shift scheduling, torque converter clutch operation and electronic pressure control (EPC). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications Transmission Speed Sensor: Specifications Vehicle speed sensor bolt ......................................................................................................................................................... 11-13 Nm (98-115 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns PROM - Programmable Read Only Memory: Customer Interest Steering - Shudder on Low Speed Turns TSB 05-17-15 09/05/05 STEERING SHUDDER DURING LOW SPEED MANEUVERS - 4.0L ENGINE FORD: 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac This article supersedes TSB 04-2-7 to update the vehicle model years and service procedure. ISSUE Some 2001-2005 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction between the tire and the road surface, which is amplified through the steering system. The condition will vary according to ambient temperature, road surface friction, and steering wheel turning speed. ACTION As design changes have taken place in the steering system, it is important to note the VEHICLE BUILD DATE and follow the appropriate steps outlined in the following Service Procedure. Perform a thorough evacuation of air from the power steering system after replacement/installation of parts. SERVICE PROCEDURE NOTE BEFORE REPLACING ANY COMPONENT, BE SURE TO CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. NOTE THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED OF AIR WITH A VACUUM AT THE RESERVOIR. FILL AND PURGE THE P/S SYSTEM FOLLOWING THE PROCEDURES CALLED OUT IN THE ON-LINE WORKSHOP MANUAL, SECTION 211-00. FOLLOWING THE EVACUATION PROCEDURE WILL REDUCE THE AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER. NOTE PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED. VEHICLES BUILT PRIOR TO APRIL 18, 2001 1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer to Workshop Manual, Section 211-02. 2. Replace the cooler assembly with service part F77Z-3D746-GA. Do not remove the existing cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the new return line from the new cooler and connect the new cooler fin pack to the existing return line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid loss from the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 4817 4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figures 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section 211-00. 6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release B28.5 or higher. Calibration files may also be obtained at the website. VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001 NOTE FOR ALL 4X2 SPORT TRAC VEHICLES BUILT AFTER 4/18/2001, PROCEED DIRECTLY TO STEP 2. THESE VEHICLES ARE ALREADY EQUIPPED WITH THE HIGH OUTPUT DISPLACEMENT PUMP (5L2Z-3A674-CA). 1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer to the Workshop Manual, Section 211-02. 2. Replace the cooler assembly with service part (F77Z-3D746-GA). Do not remove the existing cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the new return line from the new cooler and connect the new cooler fin pack to the existing return line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid loss from the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 4818 4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section 211-00. 6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release B28.5 or higher. Calibration files may also be obtained at the website. VEHICLES BUILT AFTER NOVEMBER 7, 2001 1. Remove the power steering cooler (Figure 3) from the steering gear. 2. Remove the return line from the power steering reservoir bottle (Figure 4). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 4819 3. Remove the return line from the steering gear (Figure 5). 4. Replace the current cooler (3D746) and two return lines (3A713 and 3A005) with a fin pack cooler assembly (5L2Z-3D746-A). 5. Fill and purge the P/S system following the procedures called out in the on-line Workshop Manual Section 211-00. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051715A 2001 Explorer Sport Trac 2.2 Hrs. 4X214X4, Explorer Sport 4X214X4 Vehicles Built Before 4-18-2001: Replace The Power Steering Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715A 2001-2002 Explorer Sport 2.2 Hrs. Trac 4X4, Explorer Sport 4X214X4 Vehicles Built After 4-18-01 And Before 11-7-2001: Replace The Power Steering Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715B 2001-2002 Explorer Sport 1.4 Hrs. Trac 4X2 Built After 4-18-2001: Replace The P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715C 2002-2005 Explorer Sport 1.0 Hr. Trac 4X2/4X4 Explorer Sport 4X2/4X4 Built After 11-7-2001: Replace The P/S Cooler, Fill And Purge The P/S System (Do Not Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 4820 Use With 3504A, 3504A9, 3674A, 3674D) DEALER CODING CONDITION BASIC PART NO. CODE 3A674 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped PROM - Programmable Read Only Memory: Customer Interest Steering - Shudder on Low Speed Turns or When Stopped Article No. 03-19-12 09/29/03 ^ STEERING - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS OR AT STOP ^ VIBRATION - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS OR AT STOP FORD: 2001-2003 EXPLORER SPORT 2001-2004 EXPLORER SPORT TRAC This article supersedes TSB 01-25-01 to update the part numbers and the vehicle coverage. ISSUE Some 2001-2004 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction between the tire and the road surface, which is amplified by the steering system. The condition will vary according to ambient temperature, road surface friction, and steering wheel turning speed. ACTION As design changes have taken place in the steering system, it is important to note the vehicle build date and follow the appropriate steps outlined in the following Service Procedure. Per the vehicle build date it may be necessary to replace the power steering pump and cooler, and install a no-hole check valve in the steering gear. Perform a thorough evacuation of air from the power steering system after replacement/installation of parts and reprogram the Powertrain Control Module (PCM) to the latest level calibration. NOTE THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED OF AIR WITH A VACUUM AT THE RESERVOIR. CORRECTLY FOLLOWING THE EVACUATION PROCEDURE DETAILED BELOW WILL REDUCE THE AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER. THE SHUDDER MAY STILL BE PRESENT AFTER REPLACEMENT OF THE PARTS IF THE EVACUATION PROCEDURE IS NOT PROPERLY FOLLOWED. NOTE PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED. SERVICE PROCEDURE VEHICLES BUILT PRIOR TO APRIL 18, 2001 1. Replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. NOTE DO NOT FILL, PURGE, OR LEAK CHECK THE SYSTEM AT THIS POINT SINCE THE STEERING GEAR CHECK VALVE AND COOLER MUST ALSO BE REPLACED. 2. Replace the Cooler Assembly with service part F77Z-30746-GA. (This new cooler has a larger fin pack to maintain lower fluid temperatures). BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the return line on the new cooler to be installed and connect this new fin pack assembly to the existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section 211-02 for complete replacement instructions. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 4825 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP. TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL-211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. 4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole Check Valve (E60Z-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the No-Hole Check Valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 4826 5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. 6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 8. Recheck the fluid level and, if necessary, refill. 9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 11. Reprogram the PCM to the latest level available. 12. Test drive to verify repair. VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001 1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump (Part Number 1L2Z-3A674-GA) and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. 2. Replace the Cooler Assembly with service part F77Z-3D746-GA. (This new cooler has a larger fin pack to maintain lower fluid temperatures). BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the return line on the new cooler to be installed and connect this new fin pack assembly to the existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. 4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole Check Valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 4827 6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 8. Recheck the fluid level and, if necessary, refill. 9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 11. Reprogram the PCM to the latest level available. 12. Test drive to verify repair. VEHICLES BUILT AFTER NOVEMBER 7, 2001 WARNING DO NOT INSTALL THE CHECK VALVE ON VEHICLES BUILT AFTER 11/07/2001. TRYING TO INSTALL THE CHECK VALVE WILL CAUSE DAMAGE TO THE RACK AND IT WILL HAVE TO BE REPLACED. 1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. 2. Check and fill the power steering reservoir as necessary with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. 3. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 4. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 5. Recheck the fluid level and, if necessary, refill. 6. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 7. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 4828 NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 8. Reprogram the PCM to the latest level available. (Does not apply to 2003-2004 vehicles) 9. Test drive to verify repair. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PCM Calibration Information Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 4829 SUPERSEDES: 01-25-1 WARRANTY STATUS: Eligible Under Provisions Of The New Vehicle Limited Warranty. OPERATION DESCRIPTION TIME 031912A Replace Power Steering 2.4 Hrs. Pump, P/S Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport 031912B Replace Power Steering 2.5 Hrs. Pump, P/S Cooler, Install No Hole Check Valve, Bleed P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S System A Second Time) Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport 031912C Replace Power Steering 1.6 Hrs. Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac 031912D Replace Power Steering 1.8 Hrs. Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S System A Second Time) Vehicles Built After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac 031912E Replace Power Steering 1.9 Hrs. Pump, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4X4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport 031912F Replace Power Steering 2.0 Hrs. Pump, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built After 11-07-01 But Before Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 4830 8-19-02 4x4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport 031912G Bleed Air From P/S 1.1 Hrs. System, And Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac 031912H Bleed Air From P/S 1.2 Hrs. System, And Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac 031912I Replace Power Steering 1.4 Hrs. Pump, Bleed Air From P/S System Vehicles 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912J Replace Power Steering 1.8 Hrs. Pump, Bleed Air From P/S System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912K Bleed Air From P/S 0.6 Hrs. System, Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912L Bleed Air From P/S 1.0 Hrs. System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport DEALER CODING CONDITION BASIC PART NO. CODE 3A674 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur Smell Technical Service Bulletin # 02-21-6 Date: 021028 Engine Controls/Emissions - Exhaust Sulfur Smell Article No. 02-21-6 10/28/02 ^ DRIVEABILITY - EXCESSIVE SULFUR SMELL FROM EXHAUST ^ EXHAUST - EXCESSIVE SULFUR SMELL FROM EXHAUST FORD: 2001-2002 EXPLORER SPORT 2002 EXPLORER SPORT TRAC 2002-2003 EXPLORER MERCURY: 2002-2003 MOUNTAINEER Article 02-16-6 is being republished in its entirety to update the Service Procedure and model years. ISSUE Some vehicles may exhibit excessive sulfur smell from the exhaust under certain drive modes. This may be due to the highly active state of a new catalyst, calibration factors, underbody catalyst temperature, and amount of sulfur present in the fuel. ACTION Identify year, model, and build date to identify appropriate service procedure. For applications that require installing exhaust wrap, use good quality stainless steel worm-drive hose clamps for best longevity, similar to what would commonly be used for exhaust heat shield rattle issues. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 02-16-6 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 022106A Install Exhaust Wrap And 1.4 Hrs. Perform Drive Sequence. 2002-2003 Explorer/Mountaineer 4.0L Vehicles Built 1-14-02 Through 12-02-02, 4.6L Built Prior To 12-02-02 022106B Install Exhaust Wrap, 1.6 Hrs. Reprogram Powertrain Control Module And Perform Drive Sequence. 2002-2003 Explorer/Mountaineer 4.0L Built Prior To 1-14-02 022106C Replace Catalytic 0.8 Hr. Converter And Reprogram Powertrain Control Module. 2001-2002 Explorer Sport Vehicles Built 7-24-00 Through 3-4-02, 2002 Sport Trac 11-02-01 Through 3-4-02 022106D Replace Catalytic 0.6 Hr. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur Smell > Page 4835 Converter Only. 2002 Explorer Sport/Sport Trac 3-4-02 Through 3-27-02 With Automatic Transmission, 11-02-01 Through 3-4-02 With Manual Transmission DEALER CODING CONDITION BASIC PART NO. CODE 5F250 42 OASIS CODES: 403000, 499000 Disclaimer Service Procedure 2002-2003 4 DOOR EXPLORER/MOUNTAINEER 4.0L Vehicles Built 1/14/02 Through 12/02/2002 At latest level for engine calibration. 1. Install Exhaust wrap on the pipes between the light-off and the underbody catalyst referring to the instruction sheet in the kit. 2. Refer to Drive Sequence heading to purge stored sulfur from catalyst. 3. See Contributing Factors heading for additional information. NOTE CONVERTER REPLACEMENT OR RECALIBRATION IS NOT NECESSARY. Vehicles Built Before 1/14/02 1. Verify that WDS is at the latest level, B21.0 or higher. 2. Reprogram the PCM with the latest calibration. 3. Install Exhaust wrap on the pipes between the light-off and the underbody catalyst referring to the instruction sheet in the kit. 4. Refer to Drive Sequence heading to purge stored sulfur from catalyst. 5. See Contributing Factors Heading for additional information. NOTE DO NOT REPLACE THE CONVERTER. 2002-2003 4 DOOR EXPLORER/MOUNTAINEER 4.6L Vehicles Built Prior To 12/02/2002 1. Install Exhaust wrap on the pipes between the light-off and the underbody catalyst referring to the instruction sheet in the kit. 2. Refer to Drive Sequence heading to purge stored sulfur from catalyst. 3. See Contributing Factors Heading for additional information. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur Smell > Page 4836 NOTE CONVERTER REPLACEMENT OR RECALIBRATION IS NOT NECESSARY. 2001-2002 2 DOOR EXPLORER SPORT 4.0L 7/24/00 Through 3/4/02 With 5R55E Transmission 1. Refer to 2001/2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the old catalytic converter and install the revised converter 2L2Z-5E212-DA. 2. Verify that WDS is at the latest level, B21.0 or higher. 3. Reprogram the PCM with the latest calibration only. 4. See Contributing Factors Heading for additional information. NOTE DO NOT REPLACE CONVERTER MORE THAN ONCE. 2002 2 DOOR EXPLORER SPORT/SPORT TRAC 4.0L Vehicles Built After 3/27/02 At latest level for engine calibration and converter, no service action will improve the situation. 1. See Contributing Factors Heading for additional information. 3/4/02 Through 3/27/02 1. Refer to 2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the old catalytic converter and install the revised converter 2L2Z-5E212-AB only. 2. See Contributing Factors Heading for additional information. NOTE DO NOT REPLACE CONVERTER MORE THAN ONCE OR RECALIBRATE. 2002 2 DOOR EXPLORER SPORT/SPORT TRAC 4.0L M5R4 MANUAL TRANSMISSION 11/2/01 Through 3/4/02 With Manual Transmission 1. Refer to 2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the old catalytic converter and install the revised converter 2L2Z-5E212-DA only. 2. See Contributing Factors Heading for additional information. NOTE DO NOT REPLACE CONVERTER MORE THAN ONCE OR RECALIBRATE. 2002 SPORT TRAC 4.0L 5R55E TRANSMISSION 11/2/01 Through 3/4/02 With 5R55E Transmission 1. Refer to 2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the old catalytic converter and install the revised converter 2L2Z-5E212-DA. 2. Verify that WDS is at the latest level, B21.0 or higher. 3. Reprogram the PCM with the latest calibration. 4. See Contributing Factors Heading for additional information. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur Smell > Page 4837 NOTE DO NOT REPLACE CONVERTER MORE THAN ONCE. DRIVE SEQUENCE AFTER REPAIRS COMPLETED Check engine oil and coolant levels. Verify both are at specified levels before driving vehicle. Perform highway driving at normal highway speeds for 30 miles. The optimum engine speed for this drive sequence is 3,000 to 4,500 rpm, and this can be accomplished by manually selecting the transmission gear state. The goal of the drive procedure is to maintain a constant high temperature level in the exhaust system through the use of increased engine speed. The combination of increased temperature and driving will provide a sulfur cleaning environment for the catalyst system. CONTRIBUTING FACTORS TO SULFUR SMELL Factors outside of engineering control may lead to a sulfur odor. A large contributing factor is the amount of sulfur in the fuel. Replacing a Catalytic Converter multiple times will not alleviate the sulfur odor. Several catalyst replacements on the same vehicle may actually increase customer sensitivity to an exhaust odor concern. Based on some driving habits the converter does not get hot enough to burn out stored sulfur residue and can produce a sulfur odor. For example: ^ Extended Idle - Increase sulfur odor ^ Stop and go driving - Increase sulfur odor ^ Trailer Towing - Decrease sulfur odor ^ Heavy Loads - Decrease sulfur odor Short trips - Increase sulfur odor ^ Abrupt accel/decel - Decrease sulfur odor ^ Hotter driving conditions - Decrease sulfur odor ^ Hilly terrain - Decrease sulfur odor ^ Canceling Overdrive - Decrease sulfur odor Catalysts with 5,000-10,000 Miles (8,000-16,000 kilometers) are likely to have a sulfur smell due to the highly active state of the new catalyst. Refer to symptom chart # 22 of PCED for appropriate year. Additives in fuels (Ethanol, Methanol, ETC.) can cause sulfur odor, suggest using a different fuel source. Geographic variations on sulfur odor intensity are possible due to different refineries supplying fuel to different areas of the country. California regulated fuel will exhibit less sulfur odor. Experiment with different fuel brands. Some contain more sulfur than others, which can lead to an increase in sulfur odor from the converter. Sulfur odors are an aromatic phenomenon and do not cause any durability or safety concerns with vehicle operation. To summarize for the customer, explain that sulfur is in the fuel used and the catalyst system on their vehicle as a result of the fuel and driving environment which creates a condition where sulfur has been stored in their exhaust system. The service action performed allows the sulfur to pass through the exhaust system and to clean the existing sulfur deposits. During the initial cleansing of the catalyst it is expected that a sulfur odor may still be present, and this odor may change from the "rotten egg smell" to that of a "burning match". The odor will cease with time. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur Smell > Page 4838 PCM Calibration Information Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur Smell > Page 4839 SUPERSEDES:02-16-6 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 022106A Install Exhaust Wrap And 1.4 Hrs. Perform Drive Sequence. 2002-2003 Explorer/Mountaineer 4.0L Vehicles Built 1-14-02 Through 12-02-02, 4.6L Built Prior To 12-02-02 022106B Install Exhaust Wrap, 1.6 Hrs. Reprogram Powertrain Control Module And Perform Drive Sequence. 2002-2003 Explorer/Mountaineer 4.0L Built Prior To 1-14-02 022106C Replace Catalytic 0.8 Hr. Converter And Reprogram Powertrain Control Module. 2001-2002 Explorer Sport Vehicles Built 7-24-00 Through 3-4-02, 2002 Sport Trac 11-02-01 Through 3-4-02 022106D Replace Catalytic 0.6 Hr. Converter Only. 2002 Explorer Sport/Sport Trac 3-4-02 Through 3-27-02 With Automatic Transmission, 11-02-01 Through 3-4-02 With Manual Transmission DEALER CODING CONDITION BASIC PART NO. CODE 5F250 42 OASIS CODES: 403000, 499000 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 02-6-2 > Apr > 02 > A/T - 5R55W Harsh Light/Medium Throttle Upshifts PROM - Programmable Read Only Memory: Customer Interest A/T - 5R55W Harsh Light/Medium Throttle Upshifts Article No. 02-6-2 04/01/02 TRANSMISSION - 5R55W - HARSH UPSHIFTS DURING LIGHT TO MEDIUM THROTTLE FORD: 2002 EXPLORER MERCURY: 2002 MOUNTAINEER ISSUE Some vehicles produced through 2/15/2002 equipped with the 5R55W automatic transmission may exhibit harsh 1-2, 2-3, 3-4 upshifts at light to medium throttle. This may be caused by the calibration of the Powertrain Control Module (PCM). ACTION Verify the condition. If the condition exists; reprogram the PCM with an updated calibration. If the condition persists after the reprogram, continue with normal diagnostics to pinpoint the condition. Refer to the following Service Procedure for details. SERVICE PROCEDURE Verify that at light to medium throttle positions, the 1-2, 2-3 or 3-4 shift is harsh. Prior to performing any service procedures, verify tear tag information. Refer to the PCM Calibration Information Chart in this article. If the calibration is not at the latest level, follow the procedures found in the Powertrain Control/Emissions Diagnosis (PC/ED) Service Manual to reprogram the PCM to latest calibration level. After reprogramming has been completed, the transmission adaptive strategy for pressure control on engagements must be updated. Install diagnostic equipment and monitor the Transmission Fluid Temperature (TFT). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 02-6-2 > Apr > 02 > A/T - 5R55W Harsh Light/Medium Throttle Upshifts > Page 4844 Warm the transmission fluid to at least 54°C (130°F) as indicated by the TFT. ^ Perform five (5) engagements from Park to Reverse. Each engagement must be 5 seconds apart. ^ Perform five (5) engagements from Drive to Reverse. Each engagement must be 5 seconds apart. ^ Perform five (5) engagements from Reverse to Drive. Each engagement must be 5 seconds apart. ^ Perform five (5) engagements from Neutral to Drive. Each engagement must be 5 seconds apart. NOTE ALL OF THESE ENGAGEMENTS MUST BE PERFORMED IN ORDER FOR THE ENGAGEMENT PRESSURES TO PROPERLY ADAPT WITH THE NEW CALIBRATION. Verify repair. If the condition is not corrected, continue with normal diagnostics and repair per the Workshop Manual. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 020602A Reprogram Powertrain 1.6 Hrs. Control Module (Includes Time To Update Transmission Adaptive Strategy) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 OASIS CODES: 501000, 502000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 01-24-5 > Dec > 01 > PATS - Unable to Access/Program Ignition Key/No Start, PROM - Programmable Read Only Memory: Customer Interest PATS - Unable to Access/Program Ignition Key/No Start, Article No. 01-24-5 12/10/01 ^ DRIVEABILITY - NO START - SECURILOCK PASSIVE ANTI-THEFT SYSTEM (PATS) UNABLE TO ACCESS - UNABLE TO PROGRAM IGNITION KEYS - VEHICLES PRODUCED 3/18/2001 THROUGH 4/3/2001 EQUIPPED WITH 4.0L ENGINE ONLY ^ ELECTRICAL - SECURILOCK PASSIVE ANTI-THEFT SYSTEM (PATS) - UNABLE TO ACCESS-UNABLE TO PROGRAM IGNITION KEYS - VEHICLES PRODUCED 3/18/2001 THROUGH 4/3/2001 EQUIPPED WITH 4.0L ENGINE ONLY FORD: 2002 EXPLORER MERCURY: 2002 MOUNTAINEER ISSUE Some vehicles equipped with the 4.0L engine may exhibit a condition of "unable to access" with the SecuriLock Passive Anti-Theft System (PATS). When an operation requiring PATS Security Access is attempted, an error message may be displayed, or a reference to Coded Access may be displayed. It will not be possible to enter Security Access to erase or program ignition keys into the vehicle with this condition present. This may be caused by the calibration of the Powertrain Control Module (PCM). ACTION Verify the condition. If normal diagnostics cannot pinpoint the condition, reprogram PCM to the latest level calibration. Refer to the following Service Information for details. SERVICE PROCEDURE If the New Generation Star Tester (NGS) or Worldwide Diagnostic System (WDS) displays either of the following error messages when attempting to enter Security Access for the Passive Anti-Theft System (PATS), reprogram the PCM using the NGS or WDS as necessary. ^ WDS: "The test has found a fault" followed by a screen, "Coded Access mode not supported" ^ NGS: "Security Code number: _ _ _ _ _ _ Contact local hotline for access code" Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 01-24-5 > Dec > 01 > PATS - Unable to Access/Program Ignition Key/No Start, > Page 4849 Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000, 203000, 603300 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns PROM - Programmable Read Only Memory: All Technical Service Bulletins Steering - Shudder on Low Speed Turns TSB 05-17-15 09/05/05 STEERING SHUDDER DURING LOW SPEED MANEUVERS - 4.0L ENGINE FORD: 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac This article supersedes TSB 04-2-7 to update the vehicle model years and service procedure. ISSUE Some 2001-2005 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction between the tire and the road surface, which is amplified through the steering system. The condition will vary according to ambient temperature, road surface friction, and steering wheel turning speed. ACTION As design changes have taken place in the steering system, it is important to note the VEHICLE BUILD DATE and follow the appropriate steps outlined in the following Service Procedure. Perform a thorough evacuation of air from the power steering system after replacement/installation of parts. SERVICE PROCEDURE NOTE BEFORE REPLACING ANY COMPONENT, BE SURE TO CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. NOTE THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED OF AIR WITH A VACUUM AT THE RESERVOIR. FILL AND PURGE THE P/S SYSTEM FOLLOWING THE PROCEDURES CALLED OUT IN THE ON-LINE WORKSHOP MANUAL, SECTION 211-00. FOLLOWING THE EVACUATION PROCEDURE WILL REDUCE THE AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER. NOTE PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED. VEHICLES BUILT PRIOR TO APRIL 18, 2001 1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer to Workshop Manual, Section 211-02. 2. Replace the cooler assembly with service part F77Z-3D746-GA. Do not remove the existing cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the new return line from the new cooler and connect the new cooler fin pack to the existing return line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid loss from the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 4855 4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figures 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section 211-00. 6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release B28.5 or higher. Calibration files may also be obtained at the website. VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001 NOTE FOR ALL 4X2 SPORT TRAC VEHICLES BUILT AFTER 4/18/2001, PROCEED DIRECTLY TO STEP 2. THESE VEHICLES ARE ALREADY EQUIPPED WITH THE HIGH OUTPUT DISPLACEMENT PUMP (5L2Z-3A674-CA). 1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer to the Workshop Manual, Section 211-02. 2. Replace the cooler assembly with service part (F77Z-3D746-GA). Do not remove the existing cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the new return line from the new cooler and connect the new cooler fin pack to the existing return line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid loss from the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 4856 4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section 211-00. 6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release B28.5 or higher. Calibration files may also be obtained at the website. VEHICLES BUILT AFTER NOVEMBER 7, 2001 1. Remove the power steering cooler (Figure 3) from the steering gear. 2. Remove the return line from the power steering reservoir bottle (Figure 4). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 4857 3. Remove the return line from the steering gear (Figure 5). 4. Replace the current cooler (3D746) and two return lines (3A713 and 3A005) with a fin pack cooler assembly (5L2Z-3D746-A). 5. Fill and purge the P/S system following the procedures called out in the on-line Workshop Manual Section 211-00. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051715A 2001 Explorer Sport Trac 2.2 Hrs. 4X214X4, Explorer Sport 4X214X4 Vehicles Built Before 4-18-2001: Replace The Power Steering Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715A 2001-2002 Explorer Sport 2.2 Hrs. Trac 4X4, Explorer Sport 4X214X4 Vehicles Built After 4-18-01 And Before 11-7-2001: Replace The Power Steering Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715B 2001-2002 Explorer Sport 1.4 Hrs. Trac 4X2 Built After 4-18-2001: Replace The P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715C 2002-2005 Explorer Sport 1.0 Hr. Trac 4X2/4X4 Explorer Sport 4X2/4X4 Built After 11-7-2001: Replace The P/S Cooler, Fill And Purge The P/S System (Do Not Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 4858 Use With 3504A, 3504A9, 3674A, 3674D) DEALER CODING CONDITION BASIC PART NO. CODE 3A674 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 4863 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 4864 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped PROM - Programmable Read Only Memory: All Technical Service Bulletins Steering - Shudder on Low Speed Turns or When Stopped Article No. 03-19-12 09/29/03 ^ STEERING - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS OR AT STOP ^ VIBRATION - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS OR AT STOP FORD: 2001-2003 EXPLORER SPORT 2001-2004 EXPLORER SPORT TRAC This article supersedes TSB 01-25-01 to update the part numbers and the vehicle coverage. ISSUE Some 2001-2004 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction between the tire and the road surface, which is amplified by the steering system. The condition will vary according to ambient temperature, road surface friction, and steering wheel turning speed. ACTION As design changes have taken place in the steering system, it is important to note the vehicle build date and follow the appropriate steps outlined in the following Service Procedure. Per the vehicle build date it may be necessary to replace the power steering pump and cooler, and install a no-hole check valve in the steering gear. Perform a thorough evacuation of air from the power steering system after replacement/installation of parts and reprogram the Powertrain Control Module (PCM) to the latest level calibration. NOTE THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED OF AIR WITH A VACUUM AT THE RESERVOIR. CORRECTLY FOLLOWING THE EVACUATION PROCEDURE DETAILED BELOW WILL REDUCE THE AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER. THE SHUDDER MAY STILL BE PRESENT AFTER REPLACEMENT OF THE PARTS IF THE EVACUATION PROCEDURE IS NOT PROPERLY FOLLOWED. NOTE PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED. SERVICE PROCEDURE VEHICLES BUILT PRIOR TO APRIL 18, 2001 1. Replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. NOTE DO NOT FILL, PURGE, OR LEAK CHECK THE SYSTEM AT THIS POINT SINCE THE STEERING GEAR CHECK VALVE AND COOLER MUST ALSO BE REPLACED. 2. Replace the Cooler Assembly with service part F77Z-30746-GA. (This new cooler has a larger fin pack to maintain lower fluid temperatures). BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the return line on the new cooler to be installed and connect this new fin pack assembly to the existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section 211-02 for complete replacement instructions. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 4869 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP. TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL-211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. 4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole Check Valve (E60Z-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the No-Hole Check Valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 4870 5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. 6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 8. Recheck the fluid level and, if necessary, refill. 9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 11. Reprogram the PCM to the latest level available. 12. Test drive to verify repair. VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001 1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump (Part Number 1L2Z-3A674-GA) and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. 2. Replace the Cooler Assembly with service part F77Z-3D746-GA. (This new cooler has a larger fin pack to maintain lower fluid temperatures). BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the return line on the new cooler to be installed and connect this new fin pack assembly to the existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. 4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole Check Valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 4871 6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 8. Recheck the fluid level and, if necessary, refill. 9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 11. Reprogram the PCM to the latest level available. 12. Test drive to verify repair. VEHICLES BUILT AFTER NOVEMBER 7, 2001 WARNING DO NOT INSTALL THE CHECK VALVE ON VEHICLES BUILT AFTER 11/07/2001. TRYING TO INSTALL THE CHECK VALVE WILL CAUSE DAMAGE TO THE RACK AND IT WILL HAVE TO BE REPLACED. 1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. 2. Check and fill the power steering reservoir as necessary with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. 3. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 4. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 5. Recheck the fluid level and, if necessary, refill. 6. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 7. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 4872 NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 8. Reprogram the PCM to the latest level available. (Does not apply to 2003-2004 vehicles) 9. Test drive to verify repair. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PCM Calibration Information Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 4873 SUPERSEDES: 01-25-1 WARRANTY STATUS: Eligible Under Provisions Of The New Vehicle Limited Warranty. OPERATION DESCRIPTION TIME 031912A Replace Power Steering 2.4 Hrs. Pump, P/S Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport 031912B Replace Power Steering 2.5 Hrs. Pump, P/S Cooler, Install No Hole Check Valve, Bleed P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S System A Second Time) Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport 031912C Replace Power Steering 1.6 Hrs. Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac 031912D Replace Power Steering 1.8 Hrs. Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S System A Second Time) Vehicles Built After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac 031912E Replace Power Steering 1.9 Hrs. Pump, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4X4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport 031912F Replace Power Steering 2.0 Hrs. Pump, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built After 11-07-01 But Before Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 4874 8-19-02 4x4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport 031912G Bleed Air From P/S 1.1 Hrs. System, And Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac 031912H Bleed Air From P/S 1.2 Hrs. System, And Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac 031912I Replace Power Steering 1.4 Hrs. Pump, Bleed Air From P/S System Vehicles 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912J Replace Power Steering 1.8 Hrs. Pump, Bleed Air From P/S System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912K Bleed Air From P/S 0.6 Hrs. System, Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912L Bleed Air From P/S 1.0 Hrs. System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport DEALER CODING CONDITION BASIC PART NO. CODE 3A674 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur Smell Technical Service Bulletin # 02-21-6 Date: 021028 Engine Controls/Emissions - Exhaust Sulfur Smell Article No. 02-21-6 10/28/02 ^ DRIVEABILITY - EXCESSIVE SULFUR SMELL FROM EXHAUST ^ EXHAUST - EXCESSIVE SULFUR SMELL FROM EXHAUST FORD: 2001-2002 EXPLORER SPORT 2002 EXPLORER SPORT TRAC 2002-2003 EXPLORER MERCURY: 2002-2003 MOUNTAINEER Article 02-16-6 is being republished in its entirety to update the Service Procedure and model years. ISSUE Some vehicles may exhibit excessive sulfur smell from the exhaust under certain drive modes. This may be due to the highly active state of a new catalyst, calibration factors, underbody catalyst temperature, and amount of sulfur present in the fuel. ACTION Identify year, model, and build date to identify appropriate service procedure. For applications that require installing exhaust wrap, use good quality stainless steel worm-drive hose clamps for best longevity, similar to what would commonly be used for exhaust heat shield rattle issues. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 02-16-6 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 022106A Install Exhaust Wrap And 1.4 Hrs. Perform Drive Sequence. 2002-2003 Explorer/Mountaineer 4.0L Vehicles Built 1-14-02 Through 12-02-02, 4.6L Built Prior To 12-02-02 022106B Install Exhaust Wrap, 1.6 Hrs. Reprogram Powertrain Control Module And Perform Drive Sequence. 2002-2003 Explorer/Mountaineer 4.0L Built Prior To 1-14-02 022106C Replace Catalytic 0.8 Hr. Converter And Reprogram Powertrain Control Module. 2001-2002 Explorer Sport Vehicles Built 7-24-00 Through 3-4-02, 2002 Sport Trac 11-02-01 Through 3-4-02 022106D Replace Catalytic 0.6 Hr. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur Smell > Page 4879 Converter Only. 2002 Explorer Sport/Sport Trac 3-4-02 Through 3-27-02 With Automatic Transmission, 11-02-01 Through 3-4-02 With Manual Transmission DEALER CODING CONDITION BASIC PART NO. CODE 5F250 42 OASIS CODES: 403000, 499000 Disclaimer Service Procedure 2002-2003 4 DOOR EXPLORER/MOUNTAINEER 4.0L Vehicles Built 1/14/02 Through 12/02/2002 At latest level for engine calibration. 1. Install Exhaust wrap on the pipes between the light-off and the underbody catalyst referring to the instruction sheet in the kit. 2. Refer to Drive Sequence heading to purge stored sulfur from catalyst. 3. See Contributing Factors heading for additional information. NOTE CONVERTER REPLACEMENT OR RECALIBRATION IS NOT NECESSARY. Vehicles Built Before 1/14/02 1. Verify that WDS is at the latest level, B21.0 or higher. 2. Reprogram the PCM with the latest calibration. 3. Install Exhaust wrap on the pipes between the light-off and the underbody catalyst referring to the instruction sheet in the kit. 4. Refer to Drive Sequence heading to purge stored sulfur from catalyst. 5. See Contributing Factors Heading for additional information. NOTE DO NOT REPLACE THE CONVERTER. 2002-2003 4 DOOR EXPLORER/MOUNTAINEER 4.6L Vehicles Built Prior To 12/02/2002 1. Install Exhaust wrap on the pipes between the light-off and the underbody catalyst referring to the instruction sheet in the kit. 2. Refer to Drive Sequence heading to purge stored sulfur from catalyst. 3. See Contributing Factors Heading for additional information. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur Smell > Page 4880 NOTE CONVERTER REPLACEMENT OR RECALIBRATION IS NOT NECESSARY. 2001-2002 2 DOOR EXPLORER SPORT 4.0L 7/24/00 Through 3/4/02 With 5R55E Transmission 1. Refer to 2001/2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the old catalytic converter and install the revised converter 2L2Z-5E212-DA. 2. Verify that WDS is at the latest level, B21.0 or higher. 3. Reprogram the PCM with the latest calibration only. 4. See Contributing Factors Heading for additional information. NOTE DO NOT REPLACE CONVERTER MORE THAN ONCE. 2002 2 DOOR EXPLORER SPORT/SPORT TRAC 4.0L Vehicles Built After 3/27/02 At latest level for engine calibration and converter, no service action will improve the situation. 1. See Contributing Factors Heading for additional information. 3/4/02 Through 3/27/02 1. Refer to 2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the old catalytic converter and install the revised converter 2L2Z-5E212-AB only. 2. See Contributing Factors Heading for additional information. NOTE DO NOT REPLACE CONVERTER MORE THAN ONCE OR RECALIBRATE. 2002 2 DOOR EXPLORER SPORT/SPORT TRAC 4.0L M5R4 MANUAL TRANSMISSION 11/2/01 Through 3/4/02 With Manual Transmission 1. Refer to 2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the old catalytic converter and install the revised converter 2L2Z-5E212-DA only. 2. See Contributing Factors Heading for additional information. NOTE DO NOT REPLACE CONVERTER MORE THAN ONCE OR RECALIBRATE. 2002 SPORT TRAC 4.0L 5R55E TRANSMISSION 11/2/01 Through 3/4/02 With 5R55E Transmission 1. Refer to 2002 Explorer Sport/Sport Trac Workshop Manual, Section 309-00. Remove the old catalytic converter and install the revised converter 2L2Z-5E212-DA. 2. Verify that WDS is at the latest level, B21.0 or higher. 3. Reprogram the PCM with the latest calibration. 4. See Contributing Factors Heading for additional information. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur Smell > Page 4881 NOTE DO NOT REPLACE CONVERTER MORE THAN ONCE. DRIVE SEQUENCE AFTER REPAIRS COMPLETED Check engine oil and coolant levels. Verify both are at specified levels before driving vehicle. Perform highway driving at normal highway speeds for 30 miles. The optimum engine speed for this drive sequence is 3,000 to 4,500 rpm, and this can be accomplished by manually selecting the transmission gear state. The goal of the drive procedure is to maintain a constant high temperature level in the exhaust system through the use of increased engine speed. The combination of increased temperature and driving will provide a sulfur cleaning environment for the catalyst system. CONTRIBUTING FACTORS TO SULFUR SMELL Factors outside of engineering control may lead to a sulfur odor. A large contributing factor is the amount of sulfur in the fuel. Replacing a Catalytic Converter multiple times will not alleviate the sulfur odor. Several catalyst replacements on the same vehicle may actually increase customer sensitivity to an exhaust odor concern. Based on some driving habits the converter does not get hot enough to burn out stored sulfur residue and can produce a sulfur odor. For example: ^ Extended Idle - Increase sulfur odor ^ Stop and go driving - Increase sulfur odor ^ Trailer Towing - Decrease sulfur odor ^ Heavy Loads - Decrease sulfur odor Short trips - Increase sulfur odor ^ Abrupt accel/decel - Decrease sulfur odor ^ Hotter driving conditions - Decrease sulfur odor ^ Hilly terrain - Decrease sulfur odor ^ Canceling Overdrive - Decrease sulfur odor Catalysts with 5,000-10,000 Miles (8,000-16,000 kilometers) are likely to have a sulfur smell due to the highly active state of the new catalyst. Refer to symptom chart # 22 of PCED for appropriate year. Additives in fuels (Ethanol, Methanol, ETC.) can cause sulfur odor, suggest using a different fuel source. Geographic variations on sulfur odor intensity are possible due to different refineries supplying fuel to different areas of the country. California regulated fuel will exhibit less sulfur odor. Experiment with different fuel brands. Some contain more sulfur than others, which can lead to an increase in sulfur odor from the converter. Sulfur odors are an aromatic phenomenon and do not cause any durability or safety concerns with vehicle operation. To summarize for the customer, explain that sulfur is in the fuel used and the catalyst system on their vehicle as a result of the fuel and driving environment which creates a condition where sulfur has been stored in their exhaust system. The service action performed allows the sulfur to pass through the exhaust system and to clean the existing sulfur deposits. During the initial cleansing of the catalyst it is expected that a sulfur odor may still be present, and this odor may change from the "rotten egg smell" to that of a "burning match". The odor will cease with time. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur Smell > Page 4882 PCM Calibration Information Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 02-21-6 > Oct > 02 > Engine Controls/Emissions - Exhaust Sulfur Smell > Page 4883 SUPERSEDES:02-16-6 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 022106A Install Exhaust Wrap And 1.4 Hrs. Perform Drive Sequence. 2002-2003 Explorer/Mountaineer 4.0L Vehicles Built 1-14-02 Through 12-02-02, 4.6L Built Prior To 12-02-02 022106B Install Exhaust Wrap, 1.6 Hrs. Reprogram Powertrain Control Module And Perform Drive Sequence. 2002-2003 Explorer/Mountaineer 4.0L Built Prior To 1-14-02 022106C Replace Catalytic 0.8 Hr. Converter And Reprogram Powertrain Control Module. 2001-2002 Explorer Sport Vehicles Built 7-24-00 Through 3-4-02, 2002 Sport Trac 11-02-01 Through 3-4-02 022106D Replace Catalytic 0.6 Hr. Converter Only. 2002 Explorer Sport/Sport Trac 3-4-02 Through 3-27-02 With Automatic Transmission, 11-02-01 Through 3-4-02 With Manual Transmission DEALER CODING CONDITION BASIC PART NO. CODE 5F250 42 OASIS CODES: 403000, 499000 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 02-6-2 > Apr > 02 > A/T - 5R55W Harsh Light/Medium Throttle Upshifts PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T - 5R55W Harsh Light/Medium Throttle Upshifts Article No. 02-6-2 04/01/02 TRANSMISSION - 5R55W - HARSH UPSHIFTS DURING LIGHT TO MEDIUM THROTTLE FORD: 2002 EXPLORER MERCURY: 2002 MOUNTAINEER ISSUE Some vehicles produced through 2/15/2002 equipped with the 5R55W automatic transmission may exhibit harsh 1-2, 2-3, 3-4 upshifts at light to medium throttle. This may be caused by the calibration of the Powertrain Control Module (PCM). ACTION Verify the condition. If the condition exists; reprogram the PCM with an updated calibration. If the condition persists after the reprogram, continue with normal diagnostics to pinpoint the condition. Refer to the following Service Procedure for details. SERVICE PROCEDURE Verify that at light to medium throttle positions, the 1-2, 2-3 or 3-4 shift is harsh. Prior to performing any service procedures, verify tear tag information. Refer to the PCM Calibration Information Chart in this article. If the calibration is not at the latest level, follow the procedures found in the Powertrain Control/Emissions Diagnosis (PC/ED) Service Manual to reprogram the PCM to latest calibration level. After reprogramming has been completed, the transmission adaptive strategy for pressure control on engagements must be updated. Install diagnostic equipment and monitor the Transmission Fluid Temperature (TFT). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 02-6-2 > Apr > 02 > A/T - 5R55W Harsh Light/Medium Throttle Upshifts > Page 4888 Warm the transmission fluid to at least 54°C (130°F) as indicated by the TFT. ^ Perform five (5) engagements from Park to Reverse. Each engagement must be 5 seconds apart. ^ Perform five (5) engagements from Drive to Reverse. Each engagement must be 5 seconds apart. ^ Perform five (5) engagements from Reverse to Drive. Each engagement must be 5 seconds apart. ^ Perform five (5) engagements from Neutral to Drive. Each engagement must be 5 seconds apart. NOTE ALL OF THESE ENGAGEMENTS MUST BE PERFORMED IN ORDER FOR THE ENGAGEMENT PRESSURES TO PROPERLY ADAPT WITH THE NEW CALIBRATION. Verify repair. If the condition is not corrected, continue with normal diagnostics and repair per the Workshop Manual. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 020602A Reprogram Powertrain 1.6 Hrs. Control Module (Includes Time To Update Transmission Adaptive Strategy) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 42 OASIS CODES: 501000, 502000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 01-24-5 > Dec > 01 > PATS - Unable to Access/Program Ignition Key/No Start, PROM - Programmable Read Only Memory: All Technical Service Bulletins PATS - Unable to Access/Program Ignition Key/No Start, Article No. 01-24-5 12/10/01 ^ DRIVEABILITY - NO START - SECURILOCK PASSIVE ANTI-THEFT SYSTEM (PATS) UNABLE TO ACCESS - UNABLE TO PROGRAM IGNITION KEYS - VEHICLES PRODUCED 3/18/2001 THROUGH 4/3/2001 EQUIPPED WITH 4.0L ENGINE ONLY ^ ELECTRICAL - SECURILOCK PASSIVE ANTI-THEFT SYSTEM (PATS) - UNABLE TO ACCESS-UNABLE TO PROGRAM IGNITION KEYS - VEHICLES PRODUCED 3/18/2001 THROUGH 4/3/2001 EQUIPPED WITH 4.0L ENGINE ONLY FORD: 2002 EXPLORER MERCURY: 2002 MOUNTAINEER ISSUE Some vehicles equipped with the 4.0L engine may exhibit a condition of "unable to access" with the SecuriLock Passive Anti-Theft System (PATS). When an operation requiring PATS Security Access is attempted, an error message may be displayed, or a reference to Coded Access may be displayed. It will not be possible to enter Security Access to erase or program ignition keys into the vehicle with this condition present. This may be caused by the calibration of the Powertrain Control Module (PCM). ACTION Verify the condition. If normal diagnostics cannot pinpoint the condition, reprogram PCM to the latest level calibration. Refer to the following Service Information for details. SERVICE PROCEDURE If the New Generation Star Tester (NGS) or Worldwide Diagnostic System (WDS) displays either of the following error messages when attempting to enter Security Access for the Passive Anti-Theft System (PATS), reprogram the PCM using the NGS or WDS as necessary. ^ WDS: "The test has found a fault" followed by a screen, "Coded Access mode not supported" ^ NGS: "Security Code number: _ _ _ _ _ _ Contact local hotline for access code" Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 01-24-5 > Dec > 01 > PATS - Unable to Access/Program Ignition Key/No Start, > Page 4893 Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000, 203000, 603300 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 4899 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 4900 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations Pressure Regulating Solenoid: Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 4907 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 4908 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 4909 SSA, SSC solenoids 1. TCC solenoid 2. SSB, SSD solenoids 3. EPC solenoid Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Pressure Regulating Solenoid: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. NOTE: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4912 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number or the component name in one of the the A-Z Component Lists, the Component Location description for that component can easily be found. See: Locations/Component Locations/A-Z Component List Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4913 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4914 the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4915 that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4916 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4917 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4918 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4919 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4920 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4921 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4922 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4923 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4924 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4925 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4926 Systems Overview Wire Color Code Identification Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4927 OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4928 Pressure Regulating Solenoid: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4929 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4930 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4931 Pressure Regulating Solenoid: Exploded Views Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4932 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4933 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4934 Pressure Regulating Solenoid: Electrical Diagrams Diagram 29-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4935 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4936 Pressure Regulating Solenoid: Description and Operation Electronic Pressure Control (EPC) Solenoid The electronic pressure control (EPC) solenoid is a variable force style (VFS) solenoid. The VFS type solenoid is an electro-hydraulic actuator combining a solenoid and a regulating valve. The powertrain control module (PCM) varies the current to the EPC solenoid. This action causes the solenoid to regulate transmission line pressure and line modulator pressure. This is done by producing resisting forces to the main regulator and line modulator circuits. These two circuits control clutch application pressures. The PCM has an adaptive learn strategy to electronically control the transmission which will automatically adjust the shift feel. When the battery has been disconnected or a new battery installed, certain transmission operating parameters may be lost. The PCM must relearn these parameters. During this learning process you may experience slightly firm shifts, delayed, or early shifts. This operation is considered normal and will not affect the function of the transmission. Normal operation will return once these parameters are stored by the PCM. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4937 Pressure Regulating Solenoid: Service and Repair Solenoids-Shift, Torque Converter Clutch, Electronic Pressure Control Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal If equipped, loosen the nut and position the heat shield out of the way. 4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid. 6. Remove the transmission fluid filter. 1 Remove the transmission fluid filter screw. 2 Remove the transmission fluid filter. 7. NOTE: Main control assembly does not need to be removed for solenoid service. Remove wire loom guide and protector. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4938 8. Disconnect the appropriate solenoid electrical connector. 1 Disconnect shift solenoids electrical connectors. 2 Disconnect the Torque Converter Clutch (TCC) solenoid electrical connector. 3 Disconnect the Electronic Pressure Control (EPC) solenoid electrical connector. 9. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve. CAUTION: Shift Solenoid (SSC) may pop out of its bore. This may damage the solenoid. Remove the shift solenoids. 1 Remove the wire harness 2 Remove the solenoid clamp screws. 3 Remove the solenoid clamp 4 Remove the appropriate solenoid(s) Installation 1. Install the new solenoid(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4939 2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 2W plug. Install the solenoid clamp 1 Position the solenoid clamp on the main control valve body. 2 Install the solenoid clamp screws. 3. Connect the six solenoid electrical connectors. 1 Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2 Connect the Torque Converter Clutch (TCC) solenoid electrical connector. 3 Connect the Electrical Pressure Control (EPC) solenoid electrical connector. 4. CAUTION: Excessive pressure may break the retaining pins. Install the main control valve body wire loom. Align the retaining pins to the holes in the solenoid clamps and gently press in the main control valve body wire loom guide and protector. 5. Install the transmission fluid filter. 1 Install the transmission fluid filter. 2 Install the transmission fluid filter screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4940 6. Install the transmission fluid pan. 1 Position a new transmission fluid pan gasket on the transmission fluid pan. 2 Align and install the transmission fluid pan. - Loosely install the transmission fluid pan screws. 7. Tighten the transmission fluid pan screws. - Tighten the transmission fluid pan screws in a crisscross sequence. 8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle. 10. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. 11. Fill the transmission to the correct fluid level and check for correct transmission operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications Shift Interlock Solenoid: Specifications Bolts retaining the shift lock actuator to the transmission column shift selector tube ............................................................................. 9 Nm (80 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 4944 Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator Removal and Installation 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches.Please refer to the appropriate location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable. Wait at least one minute before proceeding with the procedure to allow the backup power supply to deplete its energy. 2. Remove the lower steering column opening finish panel. 1 Remove the screws and position the hood release handle out of the way. 2 Remove the two screws from the lower steering column opening finish panel. 3 Pull outward to release the retaining clips and remove the lower steering column opening finish panel. 3. Remove the five bolts and the lower steering column opening finish panel reinforcement. 4. Remove the four nuts and lower the steering column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 4945 5. Remove the three bolts and separate the insert plate and shift lock actuator from the steering column. 6. Disconnect the electrical connector and remove the insert plate and shift lock actuator. 7. NOTE: The shift lock actuator clip is an assembly aid for the assembly plant. It is not necessary to install a new clip for installation. Remove and discard the clip. 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications Shift Solenoid: Specifications Solenoid clamp screws ........................................................................................................................ ............................................ 6-8 Nm (53-71 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 4949 Shift Solenoid: Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 4950 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 4951 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 4952 SSA, SSC solenoids 1. TCC solenoid 2. SSB, SSD solenoids 3. EPC solenoid Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. NOTE: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4955 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number or the component name in one of the the A-Z Component Lists, the Component Location description for that component can easily be found. See: Locations/Component Locations/A-Z Component List Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4956 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4957 the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4958 that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4959 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4960 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4961 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4962 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4963 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4964 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4965 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4966 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4967 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4968 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4969 Systems Overview Wire Color Code Identification Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4970 OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4971 Shift Solenoid: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4972 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4973 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4974 Shift Solenoid: Exploded Views Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4975 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4976 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4977 Shift Solenoid: Electrical Diagrams Diagram 29-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4978 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4979 Shift Solenoid: Description and Operation Shift Solenoids A, B, C, and D Four On/Off shift solenoids allow the powertrain control module to control shift scheduling. - The solenoids are two-way, normally open style. - The shift solenoids (SSA, SSB, SSC, and SSD) provide gear selection by controlling the pressures of the shift valves. - SSD is also used to apply and release the coast clutch. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4980 Shift Solenoid: Service and Repair Solenoids-Shift, Torque Converter Clutch, Electronic Pressure Control Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal If equipped, loosen the nut and position the heat shield out of the way. 4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid. 6. Remove the transmission fluid filter. 1 Remove the transmission fluid filter screw. 2 Remove the transmission fluid filter. 7. NOTE: Main control assembly does not need to be removed for solenoid service. Remove wire loom guide and protector. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4981 8. Disconnect the appropriate solenoid electrical connector. 1 Disconnect shift solenoids electrical connectors. 2 Disconnect the Torque Converter Clutch (TCC) solenoid electrical connector. 3 Disconnect the Electronic Pressure Control (EPC) solenoid electrical connector. 9. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve. CAUTION: Shift Solenoid (SSC) may pop out of its bore. This may damage the solenoid. Remove the shift solenoids. 1 Remove the wire harness 2 Remove the solenoid clamp screws. 3 Remove the solenoid clamp 4 Remove the appropriate solenoid(s) Installation 1. Install the new solenoid(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4982 2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 2W plug. Install the solenoid clamp 1 Position the solenoid clamp on the main control valve body. 2 Install the solenoid clamp screws. 3. Connect the six solenoid electrical connectors. 1 Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2 Connect the Torque Converter Clutch (TCC) solenoid electrical connector. 3 Connect the Electrical Pressure Control (EPC) solenoid electrical connector. 4. CAUTION: Excessive pressure may break the retaining pins. Install the main control valve body wire loom. Align the retaining pins to the holes in the solenoid clamps and gently press in the main control valve body wire loom guide and protector. 5. Install the transmission fluid filter. 1 Install the transmission fluid filter. 2 Install the transmission fluid filter screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4983 6. Install the transmission fluid pan. 1 Position a new transmission fluid pan gasket on the transmission fluid pan. 2 Align and install the transmission fluid pan. - Loosely install the transmission fluid pan screws. 7. Tighten the transmission fluid pan screws. - Tighten the transmission fluid pan screws in a crisscross sequence. 8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle. 10. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. 11. Fill the transmission to the correct fluid level and check for correct transmission operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations Torque Converter Clutch Solenoid: Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 4987 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 4988 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 4989 SSA, SSC solenoids 1. TCC solenoid 2. SSB, SSD solenoids 3. EPC solenoid Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. NOTE: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4992 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number or the component name in one of the the A-Z Component Lists, the Component Location description for that component can easily be found. See: Locations/Component Locations/A-Z Component List Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4993 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4994 the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4995 that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4996 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4997 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4998 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4999 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5000 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5001 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5002 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5003 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5004 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5005 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5006 Systems Overview Wire Color Code Identification Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5007 OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5008 Torque Converter Clutch Solenoid: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5009 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5010 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5011 Torque Converter Clutch Solenoid: Exploded Views Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5012 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5013 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5014 Torque Converter Clutch Solenoid: Electrical Diagrams Diagram 29-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5015 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5016 Torque Converter Clutch Solenoid: Description and Operation Torque Converter Clutch (TCC) Solenoid The torque converter clutch (TCC) solenoid is used to control the apply and release of the TCC. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5017 Torque Converter Clutch Solenoid: Service and Repair Solenoids-Shift, Torque Converter Clutch, Electronic Pressure Control Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal If equipped, loosen the nut and position the heat shield out of the way. 4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid. 6. Remove the transmission fluid filter. 1 Remove the transmission fluid filter screw. 2 Remove the transmission fluid filter. 7. NOTE: Main control assembly does not need to be removed for solenoid service. Remove wire loom guide and protector. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5018 8. Disconnect the appropriate solenoid electrical connector. 1 Disconnect shift solenoids electrical connectors. 2 Disconnect the Torque Converter Clutch (TCC) solenoid electrical connector. 3 Disconnect the Electronic Pressure Control (EPC) solenoid electrical connector. 9. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve. CAUTION: Shift Solenoid (SSC) may pop out of its bore. This may damage the solenoid. Remove the shift solenoids. 1 Remove the wire harness 2 Remove the solenoid clamp screws. 3 Remove the solenoid clamp 4 Remove the appropriate solenoid(s) Installation 1. Install the new solenoid(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5019 2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 2W plug. Install the solenoid clamp 1 Position the solenoid clamp on the main control valve body. 2 Install the solenoid clamp screws. 3. Connect the six solenoid electrical connectors. 1 Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2 Connect the Torque Converter Clutch (TCC) solenoid electrical connector. 3 Connect the Electrical Pressure Control (EPC) solenoid electrical connector. 4. CAUTION: Excessive pressure may break the retaining pins. Install the main control valve body wire loom. Align the retaining pins to the holes in the solenoid clamps and gently press in the main control valve body wire loom guide and protector. 5. Install the transmission fluid filter. 1 Install the transmission fluid filter. 2 Install the transmission fluid filter screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5020 6. Install the transmission fluid pan. 1 Position a new transmission fluid pan gasket on the transmission fluid pan. 2 Align and install the transmission fluid pan. - Loosely install the transmission fluid pan screws. 7. Tighten the transmission fluid pan screws. - Tighten the transmission fluid pan screws in a crisscross sequence. 8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle. 10. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. 11. Fill the transmission to the correct fluid level and check for correct transmission operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations Pressure Regulating Solenoid: Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 5026 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 5027 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 5028 SSA, SSC solenoids 1. TCC solenoid 2. SSB, SSD solenoids 3. EPC solenoid Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Pressure Regulating Solenoid: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. NOTE: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5031 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number or the component name in one of the the A-Z Component Lists, the Component Location description for that component can easily be found. See: Locations/Component Locations/A-Z Component List Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5032 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5033 the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5034 that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5035 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5036 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5037 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5038 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5039 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5040 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5041 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5042 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5043 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5044 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5045 Systems Overview Wire Color Code Identification Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5046 OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5047 Pressure Regulating Solenoid: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5048 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5049 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5050 Pressure Regulating Solenoid: Exploded Views Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5051 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5052 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5053 Pressure Regulating Solenoid: Electrical Diagrams Diagram 29-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5054 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5055 Pressure Regulating Solenoid: Description and Operation Electronic Pressure Control (EPC) Solenoid The electronic pressure control (EPC) solenoid is a variable force style (VFS) solenoid. The VFS type solenoid is an electro-hydraulic actuator combining a solenoid and a regulating valve. The powertrain control module (PCM) varies the current to the EPC solenoid. This action causes the solenoid to regulate transmission line pressure and line modulator pressure. This is done by producing resisting forces to the main regulator and line modulator circuits. These two circuits control clutch application pressures. The PCM has an adaptive learn strategy to electronically control the transmission which will automatically adjust the shift feel. When the battery has been disconnected or a new battery installed, certain transmission operating parameters may be lost. The PCM must relearn these parameters. During this learning process you may experience slightly firm shifts, delayed, or early shifts. This operation is considered normal and will not affect the function of the transmission. Normal operation will return once these parameters are stored by the PCM. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5056 Pressure Regulating Solenoid: Service and Repair Solenoids-Shift, Torque Converter Clutch, Electronic Pressure Control Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal If equipped, loosen the nut and position the heat shield out of the way. 4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid. 6. Remove the transmission fluid filter. 1 Remove the transmission fluid filter screw. 2 Remove the transmission fluid filter. 7. NOTE: Main control assembly does not need to be removed for solenoid service. Remove wire loom guide and protector. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5057 8. Disconnect the appropriate solenoid electrical connector. 1 Disconnect shift solenoids electrical connectors. 2 Disconnect the Torque Converter Clutch (TCC) solenoid electrical connector. 3 Disconnect the Electronic Pressure Control (EPC) solenoid electrical connector. 9. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve. CAUTION: Shift Solenoid (SSC) may pop out of its bore. This may damage the solenoid. Remove the shift solenoids. 1 Remove the wire harness 2 Remove the solenoid clamp screws. 3 Remove the solenoid clamp 4 Remove the appropriate solenoid(s) Installation 1. Install the new solenoid(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5058 2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 2W plug. Install the solenoid clamp 1 Position the solenoid clamp on the main control valve body. 2 Install the solenoid clamp screws. 3. Connect the six solenoid electrical connectors. 1 Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2 Connect the Torque Converter Clutch (TCC) solenoid electrical connector. 3 Connect the Electrical Pressure Control (EPC) solenoid electrical connector. 4. CAUTION: Excessive pressure may break the retaining pins. Install the main control valve body wire loom. Align the retaining pins to the holes in the solenoid clamps and gently press in the main control valve body wire loom guide and protector. 5. Install the transmission fluid filter. 1 Install the transmission fluid filter. 2 Install the transmission fluid filter screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5059 6. Install the transmission fluid pan. 1 Position a new transmission fluid pan gasket on the transmission fluid pan. 2 Align and install the transmission fluid pan. - Loosely install the transmission fluid pan screws. 7. Tighten the transmission fluid pan screws. - Tighten the transmission fluid pan screws in a crisscross sequence. 8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle. 10. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. 11. Fill the transmission to the correct fluid level and check for correct transmission operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Specifications Shift Interlock Solenoid: Specifications Bolts retaining the shift lock actuator to the transmission column shift selector tube ............................................................................. 9 Nm (80 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 5063 Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator Removal and Installation 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches.Please refer to the appropriate location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable. Wait at least one minute before proceeding with the procedure to allow the backup power supply to deplete its energy. 2. Remove the lower steering column opening finish panel. 1 Remove the screws and position the hood release handle out of the way. 2 Remove the two screws from the lower steering column opening finish panel. 3 Pull outward to release the retaining clips and remove the lower steering column opening finish panel. 3. Remove the five bolts and the lower steering column opening finish panel reinforcement. 4. Remove the four nuts and lower the steering column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 5064 5. Remove the three bolts and separate the insert plate and shift lock actuator from the steering column. 6. Disconnect the electrical connector and remove the insert plate and shift lock actuator. 7. NOTE: The shift lock actuator clip is an assembly aid for the assembly plant. It is not necessary to install a new clip for installation. Remove and discard the clip. 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Specifications Shift Solenoid: Specifications Solenoid clamp screws ........................................................................................................................ ............................................ 6-8 Nm (53-71 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5068 Shift Solenoid: Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5069 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5070 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5071 SSA, SSC solenoids 1. TCC solenoid 2. SSB, SSD solenoids 3. EPC solenoid Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. NOTE: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5074 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number or the component name in one of the the A-Z Component Lists, the Component Location description for that component can easily be found. See: Locations/Component Locations/A-Z Component List Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5075 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5076 the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5077 that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5078 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5079 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5080 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5081 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5082 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5083 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5084 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5085 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5086 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5087 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5088 Systems Overview Wire Color Code Identification Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5089 OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5090 Shift Solenoid: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5091 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5092 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5093 Shift Solenoid: Exploded Views Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5094 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5095 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5096 Shift Solenoid: Electrical Diagrams Diagram 29-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5097 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5098 Shift Solenoid: Description and Operation Shift Solenoids A, B, C, and D Four On/Off shift solenoids allow the powertrain control module to control shift scheduling. - The solenoids are two-way, normally open style. - The shift solenoids (SSA, SSB, SSC, and SSD) provide gear selection by controlling the pressures of the shift valves. - SSD is also used to apply and release the coast clutch. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5099 Shift Solenoid: Service and Repair Solenoids-Shift, Torque Converter Clutch, Electronic Pressure Control Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal If equipped, loosen the nut and position the heat shield out of the way. 4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid. 6. Remove the transmission fluid filter. 1 Remove the transmission fluid filter screw. 2 Remove the transmission fluid filter. 7. NOTE: Main control assembly does not need to be removed for solenoid service. Remove wire loom guide and protector. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5100 8. Disconnect the appropriate solenoid electrical connector. 1 Disconnect shift solenoids electrical connectors. 2 Disconnect the Torque Converter Clutch (TCC) solenoid electrical connector. 3 Disconnect the Electronic Pressure Control (EPC) solenoid electrical connector. 9. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve. CAUTION: Shift Solenoid (SSC) may pop out of its bore. This may damage the solenoid. Remove the shift solenoids. 1 Remove the wire harness 2 Remove the solenoid clamp screws. 3 Remove the solenoid clamp 4 Remove the appropriate solenoid(s) Installation 1. Install the new solenoid(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5101 2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 2W plug. Install the solenoid clamp 1 Position the solenoid clamp on the main control valve body. 2 Install the solenoid clamp screws. 3. Connect the six solenoid electrical connectors. 1 Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2 Connect the Torque Converter Clutch (TCC) solenoid electrical connector. 3 Connect the Electrical Pressure Control (EPC) solenoid electrical connector. 4. CAUTION: Excessive pressure may break the retaining pins. Install the main control valve body wire loom. Align the retaining pins to the holes in the solenoid clamps and gently press in the main control valve body wire loom guide and protector. 5. Install the transmission fluid filter. 1 Install the transmission fluid filter. 2 Install the transmission fluid filter screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5102 6. Install the transmission fluid pan. 1 Position a new transmission fluid pan gasket on the transmission fluid pan. 2 Align and install the transmission fluid pan. - Loosely install the transmission fluid pan screws. 7. Tighten the transmission fluid pan screws. - Tighten the transmission fluid pan screws in a crisscross sequence. 8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle. 10. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. 11. Fill the transmission to the correct fluid level and check for correct transmission operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations Torque Converter Clutch Solenoid: Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 5106 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 5107 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 5108 SSA, SSC solenoids 1. TCC solenoid 2. SSB, SSD solenoids 3. EPC solenoid Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. NOTE: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5111 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number or the component name in one of the the A-Z Component Lists, the Component Location description for that component can easily be found. See: Locations/Component Locations/A-Z Component List Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5112 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5113 the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5114 that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5115 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5116 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5117 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5118 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5119 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5120 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5121 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5122 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5123 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5124 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5125 Systems Overview Wire Color Code Identification Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5126 OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5127 Torque Converter Clutch Solenoid: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5128 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5129 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5130 Torque Converter Clutch Solenoid: Exploded Views Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5131 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5132 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5133 Torque Converter Clutch Solenoid: Electrical Diagrams Diagram 29-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5134 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5135 Torque Converter Clutch Solenoid: Description and Operation Torque Converter Clutch (TCC) Solenoid The torque converter clutch (TCC) solenoid is used to control the apply and release of the TCC. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5136 Torque Converter Clutch Solenoid: Service and Repair Solenoids-Shift, Torque Converter Clutch, Electronic Pressure Control Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal If equipped, loosen the nut and position the heat shield out of the way. 4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid. 6. Remove the transmission fluid filter. 1 Remove the transmission fluid filter screw. 2 Remove the transmission fluid filter. 7. NOTE: Main control assembly does not need to be removed for solenoid service. Remove wire loom guide and protector. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5137 8. Disconnect the appropriate solenoid electrical connector. 1 Disconnect shift solenoids electrical connectors. 2 Disconnect the Torque Converter Clutch (TCC) solenoid electrical connector. 3 Disconnect the Electronic Pressure Control (EPC) solenoid electrical connector. 9. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve. CAUTION: Shift Solenoid (SSC) may pop out of its bore. This may damage the solenoid. Remove the shift solenoids. 1 Remove the wire harness 2 Remove the solenoid clamp screws. 3 Remove the solenoid clamp 4 Remove the appropriate solenoid(s) Installation 1. Install the new solenoid(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5138 2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 2W plug. Install the solenoid clamp 1 Position the solenoid clamp on the main control valve body. 2 Install the solenoid clamp screws. 3. Connect the six solenoid electrical connectors. 1 Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2 Connect the Torque Converter Clutch (TCC) solenoid electrical connector. 3 Connect the Electrical Pressure Control (EPC) solenoid electrical connector. 4. CAUTION: Excessive pressure may break the retaining pins. Install the main control valve body wire loom. Align the retaining pins to the holes in the solenoid clamps and gently press in the main control valve body wire loom guide and protector. 5. Install the transmission fluid filter. 1 Install the transmission fluid filter. 2 Install the transmission fluid filter screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5139 6. Install the transmission fluid pan. 1 Position a new transmission fluid pan gasket on the transmission fluid pan. 2 Align and install the transmission fluid pan. - Loosely install the transmission fluid pan screws. 7. Tighten the transmission fluid pan screws. - Tighten the transmission fluid pan screws in a crisscross sequence. 8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle. 10. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. 11. Fill the transmission to the correct fluid level and check for correct transmission operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Specifications Band: Specifications Front band locknut ............................................................................................................................... .......................................... 47-61 Nm (35-45 ft. lbs.) Intermediate band locknut .............................................................................................................................................................. 47-61 Nm (35-45 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Adjustments > Front Band Adjustment Band: Adjustments Front Band Adjustment Front Band Adjustment Special Tools Special Tool(s) 1. Raise the vehicle on a hoist. 2. Disconnect the shift cable. 1 Disconnect the shift cable from the manual control lever. 2 Disconnect the shift cable from the bracket. 3. CAUTION: Do not allow front band adjustment screw to back out. Band strut can fall out of position. CAUTION: Throw the locknut away. The locknut is not reusable for assembly. Remove and discard the locknut. 4. CAUTION: Install, but do not tighten, a new locknut on the band adjustment screw. Apply petroleum jelly to the locknut seal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Adjustments > Front Band Adjustment > Page 5145 CAUTION: The servo must be installed prior to band adjustment. NOTE: The wrench will click at the specified torque. Install new locknut, do not tighten at this time. Using the special tool, tighten front band adjustment screw then, back off the front band adjustment screw exactly two (2) turns and hold that position. 5. Tighten the front band locknut. 1 Hold the front band adjustment screw stationary. 2 Tighten the front band locknut. 6. Install the shift cable. 1 Install the shift cable. 2 Install the shift cable to the manual control lever. 7. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Adjustments > Front Band Adjustment > Page 5146 Band: Adjustments Intermediate Band Adjustment Intermediate Band Adjustment 1. Raise and support the vehicle. 2. Remove the shift cable. 1 Disconnect the shift cable from the manual control lever. 2 Remove the shift cable from the bracket. 3. Remove the digital Transmission Range (TR) sensor. 4. CAUTION: Do not allow the screw to back out. Band strut can fall out of position. CAUTION: Throw the locknut away. The locknut is not reusable for assembly. Remove and discard the locknut. 5. CAUTION: Install, but do not tighten, a new locknut on the screw. Apply petroleum jelly to the locknut seal. CAUTION: The intermediate servo must be installed prior to band adjustment. NOTE: The wrench will click at the specified torque. Install new locknut, do not tighten at this time. Using the special tool, tighten the screw then, back off the screw exactly two (2) turns and hold that position. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Adjustments > Front Band Adjustment > Page 5147 6. Tighten the intermediate band locknut. 1 Hold the screw stationary. 2 Tighten the intermediate band locknut. 7. Install the digital TR sensor. 1 Position the digital TR sensor. 2 Loosely install the screws. 8. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence. 9. Install the manual control outer lever. 1 Install the manual control outer lever. 2 Install the manual control outer lever nut. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Adjustments > Front Band Adjustment > Page 5148 10. Connect the digital Transmission Range (TR) sensor electrical connector. 11. Connect the shift cable. 1 Connect the shift cable to the bracket. 2 Connect the shift cable to the manual control lever. 12. Verify that the shift cable is adjusted. 13. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 02-8-3 > Apr > 02 > A/T - 5R44E/5R55E Fluid Leak at Servo Cover Band Apply Servo: Customer Interest A/T - 5R44E/5R55E Fluid Leak at Servo Cover Article No. 02-8-3 04/29/02 TRANSMISSION - 5R44E OR 5R55E - FLUID LEAK AT SERVO COVER - VEHICLES PRODUCED 6/1/2001 THROUGH 3/31/2002 EQUIPPED WITH 2.3L, 3.0L OR 4.0L ENGINES FORD: 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER ISSUE Some vehicles equipped with a 2.3L, 3.0L or 4.0L engine and 5R44E or 5R55E automatic transmission, produced 6/1/2001 through 3/31/02, operating in cold climates, may exhibit a fluid leak at the transmission Servo Cover(s). This, may be caused by the Servo Cover. ACTION Verify the condition. If the condition exists, the Servo Cover(s) may need to be replaced with new cover(s) (Figure 1). Check the transmission fluid level and fluid condition. If fluid is just low and the fluid condition is not burnt, refer to the following Service Procedure to replace the Servo Cover(s). If the transmission shows evidence of damage due to no fluid, no engagements or severely burnt fluid, the transmission may need additional repair or replacement. Follow normal repair or replacement procedures when servicing anything other than the Servo Cover(s). SERVICE PROCEDURE Service Procedure for replacing the Front or Intermediate Servo Cover: NOTE AN IN-LINE FLUID FILTER OR AN IN-LINE FLUID FILTER KIT IS NOT REQUIRED FOR THIS PROCEDURE. 1. Remove the catalytic converter. 2. Following the procedures in the Workshop Manual "In-Vehicle Repair", "Main Control Valve Body", Section 307-01, remove the Main Control assembly. NOTE DO NOT ALLOW THE BAND ADJUSTMENT SCREW TO BACK OUT COMPLETELY OR THE BAND STRUT WILL FALL OUT OF POSITION. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 02-8-3 > Apr > 02 > A/T - 5R44E/5R55E Fluid Leak at Servo Cover > Page 5157 3. Remove and discard the band lock nut, then back out the adjusting screw three to four turns. 4. Install special service tool 307-340 (T95L-77028-A). 5. Tighten special tool to compress the servo spring. CAUTION THE SERVO COVER IS UNDER SPRING TENSION. 6. Remove the Servo Cover retaining ring. 7. Slowly remove the tension on the J-hook nut and remove the Servo Cover compressor. NOTE DO NOT ALLOW THE PISTON TO COME OUT OF THE BORE. 8. Tap lightly on the cover, then remove the cover. NOTE DO NOT DAMAGE THE COVER SEALS DURING INSTALLATION. DO NOT PRESS SERVO COVER AND SEALS PAST THE RELIEF HOLE IN THE CASE OR SEALS MAY BE DAMAGED. 9. Lubricate Servo Cover Seal and install a new Servo Cover Assembly onto the piston and into the piston bore Refer to the Servo Cover Application Chart for Servo Cover applications. 10. Install special service tool 307-340 (T95L-77028-A). 11. Tighten special tool to compress the Servo Cover and spring. 12. Install retaining ring. 13. Slowly remove the tension on the J-hook nut and remove the Servo Cover compressor. Clean residual fluid from Servo Cover area. NOTE INSTALL, BUT DO NOT TIGHTEN, A NEW LOCK NUT ON THE SCREW. NOTE THE WRENCH WILL CLICK AT THE SPECIFIED TORQUE. NOTE IF REPLACING BOTH SERVO COVERS, ORDER TWO (2) NEW LOCK NUTS. 14. Apply petroleum jelly to the lock nut seal. Install new locknut, but do not tighten at this time. Using special service tool 307-S022, tighten the band adjusting screw to 14 N.m (10 Lb-ft), then back oft the adjusting screw exactly two (2) turns and hold that position. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 02-8-3 > Apr > 02 > A/T - 5R44E/5R55E Fluid Leak at Servo Cover > Page 5158 15. Hold the band adjusting screw stationary and tighten the band locknut to 47-61 N.m (35-44 lb-ft). 16. Following the procedures in the Workshop Manual "In-Vehicle Repair", "Main Control Valve Body", Section 307-01, Install the Main Control assembly. 17. Reinstall the catalytic converter. Parts Block OTHER APPLICABLE ARTICLES: 02-8-2 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 7L173 01 OASIS CODES: 504000, 510000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 02-8-3 > Apr > 02 > A/T - 5R44E/5R55E Fluid Leak at Servo Cover Band Apply Servo: All Technical Service Bulletins A/T - 5R44E/5R55E Fluid Leak at Servo Cover Article No. 02-8-3 04/29/02 TRANSMISSION - 5R44E OR 5R55E - FLUID LEAK AT SERVO COVER - VEHICLES PRODUCED 6/1/2001 THROUGH 3/31/2002 EQUIPPED WITH 2.3L, 3.0L OR 4.0L ENGINES FORD: 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER ISSUE Some vehicles equipped with a 2.3L, 3.0L or 4.0L engine and 5R44E or 5R55E automatic transmission, produced 6/1/2001 through 3/31/02, operating in cold climates, may exhibit a fluid leak at the transmission Servo Cover(s). This, may be caused by the Servo Cover. ACTION Verify the condition. If the condition exists, the Servo Cover(s) may need to be replaced with new cover(s) (Figure 1). Check the transmission fluid level and fluid condition. If fluid is just low and the fluid condition is not burnt, refer to the following Service Procedure to replace the Servo Cover(s). If the transmission shows evidence of damage due to no fluid, no engagements or severely burnt fluid, the transmission may need additional repair or replacement. Follow normal repair or replacement procedures when servicing anything other than the Servo Cover(s). SERVICE PROCEDURE Service Procedure for replacing the Front or Intermediate Servo Cover: NOTE AN IN-LINE FLUID FILTER OR AN IN-LINE FLUID FILTER KIT IS NOT REQUIRED FOR THIS PROCEDURE. 1. Remove the catalytic converter. 2. Following the procedures in the Workshop Manual "In-Vehicle Repair", "Main Control Valve Body", Section 307-01, remove the Main Control assembly. NOTE DO NOT ALLOW THE BAND ADJUSTMENT SCREW TO BACK OUT COMPLETELY OR THE BAND STRUT WILL FALL OUT OF POSITION. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 02-8-3 > Apr > 02 > A/T - 5R44E/5R55E Fluid Leak at Servo Cover > Page 5164 3. Remove and discard the band lock nut, then back out the adjusting screw three to four turns. 4. Install special service tool 307-340 (T95L-77028-A). 5. Tighten special tool to compress the servo spring. CAUTION THE SERVO COVER IS UNDER SPRING TENSION. 6. Remove the Servo Cover retaining ring. 7. Slowly remove the tension on the J-hook nut and remove the Servo Cover compressor. NOTE DO NOT ALLOW THE PISTON TO COME OUT OF THE BORE. 8. Tap lightly on the cover, then remove the cover. NOTE DO NOT DAMAGE THE COVER SEALS DURING INSTALLATION. DO NOT PRESS SERVO COVER AND SEALS PAST THE RELIEF HOLE IN THE CASE OR SEALS MAY BE DAMAGED. 9. Lubricate Servo Cover Seal and install a new Servo Cover Assembly onto the piston and into the piston bore Refer to the Servo Cover Application Chart for Servo Cover applications. 10. Install special service tool 307-340 (T95L-77028-A). 11. Tighten special tool to compress the Servo Cover and spring. 12. Install retaining ring. 13. Slowly remove the tension on the J-hook nut and remove the Servo Cover compressor. Clean residual fluid from Servo Cover area. NOTE INSTALL, BUT DO NOT TIGHTEN, A NEW LOCK NUT ON THE SCREW. NOTE THE WRENCH WILL CLICK AT THE SPECIFIED TORQUE. NOTE IF REPLACING BOTH SERVO COVERS, ORDER TWO (2) NEW LOCK NUTS. 14. Apply petroleum jelly to the lock nut seal. Install new locknut, but do not tighten at this time. Using special service tool 307-S022, tighten the band adjusting screw to 14 N.m (10 Lb-ft), then back oft the adjusting screw exactly two (2) turns and hold that position. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 02-8-3 > Apr > 02 > A/T - 5R44E/5R55E Fluid Leak at Servo Cover > Page 5165 15. Hold the band adjusting screw stationary and tighten the band locknut to 47-61 N.m (35-44 lb-ft). 16. Following the procedures in the Workshop Manual "In-Vehicle Repair", "Main Control Valve Body", Section 307-01, Install the Main Control assembly. 17. Reinstall the catalytic converter. Parts Block OTHER APPLICABLE ARTICLES: 02-8-2 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 7L173 01 OASIS CODES: 504000, 510000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Page 5166 Band Apply Servo: Specifications Low/reverse servo cover screws ............................................................................................................................................. 12-14 Nm (106-124 inch lbs.) Transmission servo heat shield nut ............................................................................................................................................... 8-11 Nm (71-97 inch lbs.) Transmission servo heat shield stud ........................................................................................................................................ 12-16 Nm (106-142 inch lbs.) Transmission servo heat shield stud ........................................................................................................................................ 12-16 Nm (106-142 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Front Servo Band Apply Servo: Service and Repair Front Servo Front Servo Special Tool(s) Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support vehicle. 3. Remove the shift cable. 1 Disconnect the shift cable from the manual control lever. 2 Remove the shift cable from the bracket. 4. Remove the digital Transmission Range (TR) sensor. 5. Remove the main control valve body. 6. Remove the Three Way Catalytic Converter (TWC). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Front Servo > Page 5169 7. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. Loosen the nut and position the heat shield out of the way. 8. Remove the front band locknut and unscrew the front band adjusting screw. - Discard the front band locknut after removal. 9. CAUTION: The servo cover is under spring pressure. Using the special tool, remove the front band servo cover retaining ring. Slowly remove tension on the J-hook nut and remove the servo cover compressor. 10. CAUTION: The special tool should be used to prevent damage to servo and bore. Using the special tool, remove the front band servo cover, servo piston and servo piston spring. Insert the special tool into the transmission case, locate on servo rod, and remove the front band servo cover, servo piston and servo piston spring. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Front Servo > Page 5170 Installation 1. Assemble the front band servo cover, front band servo piston and the servo piston spring. 1 Install the front band servo piston into the front band servo cover. 2 Install the servo piston spring on the front band servo piston. 2. CAUTION: Do not damage O-ring during installation. Do not press servo cover and O-ring past relief hole in case, or O-ring damage may occur. Install the front band servo assembly into the transmission case. Lubricate the front band servo cover O-ring with petroleum jelly. 3. Using the special tool, install the front band servo cover retaining ring. 4. Install the main control valve body. 5. Adjust the front band. 6. If equipped, position the transmission servo heat shield on the transmission and install the nut. 7. Install the three way catalytic converter. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Front Servo > Page 5171 8. Install the shift cable. 1 Install the shift cable. 2 Install the shift cable to the manual control lever. 9. Install the digital Transmission Range (TR) sensor. 10. Lower the vehicle. 11. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. 12. Fill the transmission to the correct fluid level and check for correct transmission operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Front Servo > Page 5172 Band Apply Servo: Service and Repair Intermediate Servo Intermediate Servo Special Tools Special Tool(s) Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Remove the shift cable. 1 Disconnect the shift cable from the manual control lever. 2 Remove the shift cable from the bracket. 4. Remove the digital Transmission Range (TR) sensor. 5. Remove the Three Way Catalytic Converter (TWC). 6. Remove the main control valve body. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Front Servo > Page 5173 7. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. Loosen the nut and position the heat shield out of the way. 8. Remove the intermediate band locknut and unscrew the screw. - Discard the intermediate band locknut after removal. 9. CAUTION: The servo cover is under spring tension. Use caution when removing. Using the special tool, remove the intermediate band servo cover retaining ring. Slowly remove tension on the J-hook nut and remove the servo cover compressor. 10. CAUTION: The special tool should be used to prevent damage to the servo, servo cover and bore. Using the special tool, remove the intermediate band servo cover, intermediate band servo piston and servo piston spring. Insert the special tool into the transmission case, and remove the servo cover, intermediate band servo piston and servo piston spring. Installation Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Front Servo > Page 5174 1. Assemble the intermediate band servo cover, intermediate band servo piston and the servo piston spring. 1 Install the intermediate band servo piston into the intermediate band servo cover. 2 Install the servo piston spring on the intermediate band servo piston. 2. CAUTION: Do not damage O-ring during installation. Do not press servo cover and O-ring past relief hole in case, or O-ring damage may occur. Install the intermediate band servo piston assembly into the transmission case. Lubricate intermediate band servo cover O-ring with petroleum jelly. 3. Using the special tool, install the intermediate band servo cover retaining ring. 4. Adjust the intermediate band. 5. Install the main control valve body. 6. Install the Digital Transmission Range (TR) sensor. 7. If equipped, position the transmission servo heat shield on the transmission and install the nut. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Front Servo > Page 5175 8. Install the shift cable. 1 Install the shift cable. 2 Install the shift cable to the manual control lever. 9. Install the three way catalytic converter. 10. Lower the vehicle. 11. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm anal this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. 12. Fill the transmission to the correct fluid level and check for correct transmission operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Front Servo > Page 5176 Band Apply Servo: Service and Repair Low/Reverse Servo Assembly Low/Reverse Servo Assembly Removal 1. Position the vehicle on a hoist. Place in NEUTRAL. 2. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts, either soft or firm, and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. If equipped, loosen the nut and position the heat shield out of the way. 4. Place a drain pan under the transmission fluid pan. 5. Drain transmission fluid. - Remove all the transmission fluid pan bolts except for two in the front. Loosen the two front transmission fluid pan screws. Pry the rear of the transmission fluid pan down and allow fluid to drain. After fluid is drained, remove the front two transmission fluid pan screws. 6. Remove the transmission fluid pan. 1 Remove the transmission fluid pan. 2 Remove and discard the transmission fluid pan gasket. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Front Servo > Page 5177 7. Remove the transmission fluid filter. 1 Remove the transmission fluid filter screw. 2 Remove the transmission fluid filter. 8. Remove the low/reverse band servo cover. 1 Remove the low/reverse band servo cover screws. 2 Remove the low/reverse band servo cover and gasket. Discard the low/reverse servo separator plate cover gasket. 9. Remove the low/reverse band servo piston and rod assembly. Installation 1. Clean and inspect the low/reverse band servo piston bore and the low/reverse band servo piston and rod. 2. Install the low/reverse band servo piston and rod. 1 Install the low/reverse band servo piston and rod assembly. 2 Install a new low/reverse band servo separator plate cover gasket. 3 Install the low/reverse band servo cover. - Loosely install the low/reverse band servo piston cover screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Front Servo > Page 5178 3. Tighten the servo cover screws in the sequence shown. 4. Install the transmission fluid filter. 5. Install the transmission fluid pan. 1 Position a new transmission fluid pan gasket on the transmission fluid pan. 2 Install and align the transmission fluid pan. - Loosely install the transmission fluid pan screws. 6. Tighten the transmission fluid pan screws. - Tighten the transmission fluid pan screws in a crisscross sequence. 7. Lower the vehicle. 8. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer need, to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Front Servo > Page 5179 Connect the battery ground cable. 9. Fill the transmission to the correct fluid level and check for correct transmission operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Bell Housing, A/T > Component Information > Specifications Bell Housing: Specifications Converter housing screws ............................................................................................................................................................. 36-52 Nm ((27-39 ft. lbs.) Converter housing-to-engine screws .............................................................................................................................................. 40-55 Nm (30-41 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Specifications Channel Plate: Specifications Separator plate screws ........................................................................................................................ ............................................ 6-8 Nm (53-71 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Fluid - A/T > Component Information > Specifications > Capacity Specifications Differential Fluid - A/T: Capacity Specifications "Information not provided by the manufacturer" Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 5191 Differential Fluid - A/T: Fluid Type Specifications "Information not provided by the manufacturer" Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Specifications Extension Housing: Specifications Extension housing screws and studs ............................................................................................................................................... 36-52 Nm (27-39 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - 5R55W Correct Fluid Checking Procedure Technical Service Bulletin # 01-7-6 Date: 010420 A/T - 5R55W Correct Fluid Checking Procedure Article No. 01-7-6 04/20/01 TRANSMISSION - 5R55W - CORRECT TRANSMISSION FLUID CHECKING PROCEDURE FORD: 2002 EXPLORER MERCURY: 2002 MOUNTAINEER ISSUE Improper checking of the transmission fluid level may result in the misdiagnosis of transmission concerns. ACTION To properly check the transmission fluid level, use the procedures as found in the current CD-ROM, Workshop Manual, STARS Broadcast, and as listed in this TSB. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 504000, 510000 Service Procedure SPECIAL SERVICE TOOL(S) 205-025 - Gauge, Drive Pinion Angle (T68P-4602-A) (Figure 1). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - 5R55W Correct Fluid Checking Procedure > Page 5199 418-F224 - Worldwide Diagnostic System (WDS) - New Generation Star (NGS) Tester 418-F205 or equivalent scan tool (Figure 2). 303-D104 - Oil Suction Gun (D94T-9000-A) (Figure 3). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - 5R55W Correct Fluid Checking Procedure > Page 5200 307-437 - Adapter, Fluid Level and Fill Plug (Figure 4). NOTE LEFT SIDE OF CASE IS SHOWN. FLUID LEVEL CHECK (Fluid Fill Reference Figure 5) 1. Using the scan tool (WDS), monitor the transmission fluid temperature (TFT) using PID: TFT. 2. Start the vehicle. NOTE ENGINE IDLE SPEED IS APPROXIMATELY 650 RPM. 3. Run the engine until the transmission fluid temperature is between 27°C-49°C (80°F-120° F). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - 5R55W Correct Fluid Checking Procedure > Page 5201 4. Move the range selector lever slowly through each gear, stopping in each position and allowing the transmission to engage (Figure 6). 5. Place the range selector lever in the Park position. 6. Raise and support the vehicle with the engine running. For additional information, refer to Workshop Manual Section 100-02. 7. If needed, use special tool 205-025 to set the vehicle as close to level as possible (Figure 7). 8. Place a suitable drain pan under the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - 5R55W Correct Fluid Checking Procedure > Page 5202 9. With the transmission range selector lever in the Park position, hold the larger drain plug with a wrench and remove the small (center) fluid level indicating plug using a 3/16 inch Allen key (Figure 8). 10. Allow the fluid to drain. Wait approximately 1 minute. When the fluid comes out as a thin stream or a drip, the fluid is at the correct level (Figure 9). 11. If no fluid comes out of the hole, fluid will need to be added. Continue with this procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - 5R55W Correct Fluid Checking Procedure > Page 5203 12. Install special tool 307-437 into the pan (Figure 10). 13. Using special tool 303-D104, extract approximately 0.47 L (1 pint) of clean automatic transmission fluid from a suitable container (Figure 11). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - 5R55W Correct Fluid Checking Procedure > Page 5204 14. Using the special tools, fill the transmission with clean automatic transmission fluid (Figure 12). 15. Remove special tool 303-D104. 16. Allow the fluid to drain. Wait approximately 1 minute. When the fluid comes out as a thin stream or drip, the fluid is at the correct level. If no fluid drains from the plug, keep adding fluid in 0.24 L (1/2 pint) increments until the fluid starts to drain from the plug (Figure 13). 17. Remove the special tool from the pan (Figure 10). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - 5R55W Correct Fluid Checking Procedure > Page 5205 18. Reinstall the small (center) fluid level indicating plug using a 3/16 inch Allen key. Torque to 10 N.m (89 lb-in) (Figure 14). 19. Remove special tool 205-025 level gauge (if used). 20. Lower the vehicle. 21. Remove the WDS. 22. Check the operation of the transmission by moving the range selector lever slowly through each gear, stopping in each position and allowing the transmission to engage. 23. Raise and support the vehicle with the engine running and check for any leaks. For additional information, refer to Workshop Manual Section 100-02. 24. Lower the vehicle and shut off the engine. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid .............................................................................................................................. ...................................................... 9.5L (10.0 quarts) Note: Approximate dry capacity includes cooler and tubes. Fluid level procedures should be used to determine actual fluid requirements and fluid specification. DO NOT OVERFILL. If it is necessary to add or change fluid, use only fluid, which has been certified by the supplier as meeting the Ford Motor Company specification shown. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 5208 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ..................................................................................................................................................... ............................................ MERCON V XT-5-QM Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition Fluid - A/T: Service and Repair A/T Fluid Level Check and Condition With Dip Stick Check Fluid Level and Condition CAUTION: The vehicle should not be driven if the fluid level indicator shows the fluid below the Do Not Drive mark or internal failure could result. NOTE: Automatic transmission fluid expands when warmed. To obtain an accurate fluid level check, drive the vehicle until warmed, approximately 30 km (18.75 miles). If the vehicle has been operated for an extended period at high speeds, in city traffic, during hot weather or while pulling a trailer. the vehicle should be turned off for about 30 minutes to allow the fluid to cool before checking. NOTE: The transmission fluid level should be checked at normal operating temperatures, 66 - 77 °C (150 - 170 °F), on a level surface. The normal operating temperature can be reached after approximately 32 km (20 miles) of driving. However, you can check the fluid level without driving if the outside temperature is above 10 °C (50 °F). When the vehicle has not been driven, and the outside is above 10 °C (50 °F), the fluid level should be between the holes on the indicator. If the transmission fluid is to be checked when the fluid is at room temperature, the fluid level indicator could indicate that fluid should be added if the indicator is misread. If fluid is added at this time, an overfill condition could result when the vehicle reaches operating temperature of 66 - 77 °C (150 170 °F). 1. Drive the vehicle 30 km (18.75 miles) or until the vehicle reaches normal operating temperatures. 2. Park the vehicle on a level surface and apply the parking brake. 3. With the parking brake applied and your foot on the brake pedal, start the engine and move the range selector lever through all the gear ranges. Allow sufficient time for each gear to engage. 4. Place the range selector lever in (P) park and leave the engine running. 5. Remove the fluid level indicator and wipe it clean with a lint free cloth. 6. Install the fluid level indicator until it is fully seated into the filler tube. 7. Remove the fluid level indicator and inspect the fluid level. The fluid level should be in the designated area for normal and room temperature. High Fluid Level Fluid levels above the safe range may result in transmission failure. An overfill condition of transmission fluid may cause shift or engagement concerns and possible damage. High fluid levels can be caused by an overheating condition. A fluid level that is too high may cause the fluid to become aerated due to the churning action of the rotating internal parts. This will cause erratic control pressure, foaming, loss of fluid from the vent tube and possible transmission malfunction and/or damage. If an overfill reading is indicated drain and refill the transmission. Low Fluid Level DO NOT DRIVE the vehicle if the fluid level is below the hole at the bottom of the fluid level indicator or not on the fluid level indicator, and the outside temperatures are above 10 °C (50 °F). A low fluid level could result in poor transmission engagement, slipping, malfunction and/or damage. This could also indicate a leak in one of the transmission seals or gaskets. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition > Page 5211 Adding Fluid CAUTION: The use of any other type of transmission fluid than specified could result in transmission malfunction and/or damage. An overfill condition of transmission fluid may cause shift or engagement concerns and possible damage. Before adding fluid be sure that the correct type is being used. If fluid needs to be added, add fluid in 0.25 L (1/2 pint) increments through the filler tube. Do not overfill the fluid. Fluid Condition Check 1. Check the fluid level. 2. Observe the color and the odor. The color under normal circumstances should be dark reddish, not brown or black. 3. Hold the fluid level indicator over a white facial tissue and allow the fluid to drip onto the facial tissue and examine the stain. 4. If evidence of solid material is found, the transmission fluid pan should be removed for further inspection. 5. If the stain is a foamy pink color, this may indicate coolant in the transmission. The engine cooling system should also be inspected at this time. 6. If fluid contamination or transmission failure is confirmed by the sediment in the bottom of the transmission fluid pan, the transmission must be disassembled and completely cleaned. This includes the torque converter and cooler lines. 7. Carry out diagnostic checks and adjustments. Without Dip Stick Fluid Pan, Gasket and Filter Removal 1. Raise and support the vehicle. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. If equipped, loosen the nut and position the heat shield out of the way. 2. Place a drain pan under the transmission fluid pan. 3. Drain transmission fluid. - Disconnect the LH three-way catalytic converter heated oxygen sensor connectors and remove the converter. - Remove all the transmission fluid pan bolts except for two in the front. Loosen the two front transmission fluid pan screws. Pry the rear of the transmission fluid pan down and allow fluid to drain. After fluid is drained, remove the front two transmission fluid pan screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition > Page 5212 4. Remove the transmission fluid pan. 1. Remove the transmission fluid pan. 2. Remove and discard the transmission fluid pan gasket. 5. Remove and discard the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 6. Clean and inspect the transmission fluid pan and magnet. Clean all mating surfaces. 7. Flush the transmission fluid cooler and transmission fluid cooler lines. Installation 1. CAUTION: Lubricate fluid filter O-rings with MERCON(R) V Automatic Transmission Fluid XT-5-QM meeting Ford specification MERCON (R) V or they may be damaged. Lube and install new O-rings onto the transmission fluid filter. Install a new transmission fluid filter. ^ Position transmission fluid filter on the main control valve body. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition > Page 5213 2. CAUTION: Make sure wire harness is not pinched under filter. Install transmission fluid filter screw. 3. Position the oil pan magnet in the transmission fluid pan. 4. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Install and align the transmission fluid pan. ^ Loosely install the transmission fluid pan screws. 5. Tighten the transmission fluid pan screws. ^ Use a crisscross sequence to tighten the transmission fluid pan screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition > Page 5214 6. If equipped, position the servo heat shield over the servos and clip it to the pan rail. 7. Lower the vehicle. 8. NOTE: When filling a dry transmission and converter, start with a minimum of 3.7 liters (4 quarts). Fill transmission to the correct fluid level and check for correct transmission operation. ^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM meeting Ford specification MERCON(R) V. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition > Page 5215 Fluid - A/T: Service and Repair Transmission Fluid Drain and Refill With Dip Stick Transmission Fluid Level Check NOTE: This drain and fill procedure is referenced from TSB # 02-20-3 and applies to 5R55N, 5R55S, and 5R55W Automatic Transmissions. Part 2 Of 2 Special Tool(s) Fluid Fill Reference Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition > Page 5216 NOTE: Left side of case is shown. 1. Using the scan tool (WDS), monitor the Transmission Fluid Temperature (TFT) using PID TFT. 2. Start the vehicle. 3. NOTE: Engine idle speed is approximately 650 rpm. While proceeding with this procedure, run the engine until the transmission fluid temperature is between 27°C - 49°C (80°F - 120°F). 4. Move the range selector lever slowly through each gear, stopping in each position and allowing the transmission to engage. 5. Place the range selector lever in the PARK position. 6. With the engine running, position the vehicle on a hoist and set it as close to level as possible. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition > Page 5217 7. Hold the larger drain plug with a wrench and remove the small (center) fluid level indicating plug using a 3/16-inch Allen key. 8. Install the special tool into the pan. 9. NOTE: Prior to filling the special tool with clean transmission fluid, make sure that the canister is clean. Fill the special tool with clean automatic transmission fluid. 10. Hang the special tool under the vehicle. Position it upright and close to the transmission. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition > Page 5218 11. Connect the special tools. ^ Connect the open end of the fluid hose from the Fluid Transporter/Evacuator/Injector to the Fluid Level and Fill Plug Adapter at the bottom of the transmission fluid pan. 12. Apply a maximum of 206.85 kPa (30 psi) to the open end of the vacuum/pressure hose from the special tool. Fluid will immediately start flowing out of the special tool into the transmission fluid pan. 13. Add one pint of transmission fluid into the fluid pan. Stop the process by releasing the air pressure and removing the air nozzle from the end of the hose. 14. Inspect the fluid level in the special tool. If the fluid drains back into the canister, the transmission is full. If no fluid drains back, more fluid will need to be added. Repeat steps 12 and 13. 15. Once the transmission is full, place a hand vacuum pump on the open end of the vacuum/pressure hose of the special tool and apply vacuum to the system. This will pull out any extra fluid trapped in the system and direct it into the corner 16. Allow the fluid to drain. Make sure that the fluid temperature is between 27°C - 49°C (80°F 120°F). When the fluid comes out as a thin stream or drip, the fluid is at the correct level. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition > Page 5219 17. Reinstall the small (center) fluid level indicating plug using a 3/16 inch Allen key. 18. Check the operation of the transmission by moving the range selector lever slowly through each gear, stopping in each position and allowing the transmission to engage. Without Dip Stick Fluid Pan, Gasket and Filter Removal 1. Raise and support the vehicle. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. If equipped, loosen the nut and position the heat shield out of the way. 2. Place a drain pan under the transmission fluid pan. 3. Drain transmission fluid. - Disconnect the LH three-way catalytic converter heated oxygen sensor connectors and remove the converter. - Remove all the transmission fluid pan bolts except for two in the front. Loosen the two front transmission fluid pan screws. Pry the rear of the transmission fluid pan down and allow fluid to drain. After fluid is drained, remove the front two transmission fluid pan screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition > Page 5220 4. Remove the transmission fluid pan. 1. Remove the transmission fluid pan. 2. Remove and discard the transmission fluid pan gasket. 5. Remove and discard the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 6. Clean and inspect the transmission fluid pan and magnet. Clean all mating surfaces. 7. Flush the transmission fluid cooler and transmission fluid cooler lines. Installation 1. CAUTION: Lubricate fluid filter O-rings with MERCON(R) V Automatic Transmission Fluid XT-5-QM meeting Ford specification MERCON (R) V or they may be damaged. Lube and install new O-rings onto the transmission fluid filter. Install a new transmission fluid filter. ^ Position transmission fluid filter on the main control valve body. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition > Page 5221 2. CAUTION: Make sure wire harness is not pinched under filter. Install transmission fluid filter screw. 3. Position the oil pan magnet in the transmission fluid pan. 4. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Install and align the transmission fluid pan. ^ Loosely install the transmission fluid pan screws. 5. Tighten the transmission fluid pan screws. ^ Use a crisscross sequence to tighten the transmission fluid pan screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition > Page 5222 6. If equipped, position the servo heat shield over the servos and clip it to the pan rail. 7. Lower the vehicle. 8. NOTE: When filling a dry transmission and converter, start with a minimum of 3.7 liters (4 quarts). Fill transmission to the correct fluid level and check for correct transmission operation. ^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM meeting Ford specification MERCON(R) V. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition > Page 5223 Fluid - A/T: Service and Repair Vehicles Not Equipped With Torque Converter Drain Plug Transmission Fluid Drain and Refill- Vehicles Not Equipped With Torque Converter Drain Plug Draining CAUTION: Use only clean automatic transmission fluid. Do not use any supplemental transmission fluid additives, treatments or cleaning agents. The use of these materials can affect the operation of the transmission, resulting in internal component failure. 1. With the vehicle in PARK, position on a hoist. 2. NOTE: If equipped, the transmission servo heat shield must be unclipped from the fluid pan rail and positioned aside for fluid pan removal. If equipped, loosen the nut and position the heat shield aside. 3. Place a drain pan under the transmission fluid pan. 4. Drain the transmission fluid. ^ Remove all the transmission fluid pan bolts except for two in the front. Loosen the two front transmission fluid pan screws. Pry the rear of the transmission fluid pan down and allow the fluid to drain. After the fluid is drained, remove the front two transmission fluid pan screws. 5. Remove the transmission fluid pan. 1. Remove the transmission fluid pan. 2. Remove and discard the transmission fluid pan gasket. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition > Page 5224 6. Clean and inspect the transmission fluid pan and magnet. Clean all mating surfaces. Refill 1. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Install and align the transmission fluid pan ^ Loosely install the transmission fluid pan screws. 2. Tighten the transmission fluid pan screws. ^ Tighten the transmission fluid pan screws in a crisscross sequence. 3. If equipped, position the servo heat shield over the servos and clip it to the pan rail. 4. Lower the vehicle. 5. NOTE: When filling a dry transmission and converter, start with a minimum of 3.7 liters (4 quarts). With the engine running and the transmission at normal operating temperature 66-77°C (150-170°F), check and adjust the transmission fluid level and check for any leaks. If fluid is needed, add fluid in increments of 0.24 liter (0.5 pint) until the correct level is achieved (fluid should be in the Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition > Page 5225 cross-hatched area of the fluid level indicator). 6. Apply the park brake, and start the engine. 7. Move the range selector lever through all the gears. 8. Check the transmission fluid level. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition > Page 5226 Fluid - A/T: Service and Repair Automated Equipment Transmission Fluid Drain and Refill-Automated Equipment Special Tool(s) Draining CAUTION: Use only clean automatic transmission fluid. Do not use any supplemental transmission fluid additives, treatments or cleaning agents. The use of these materials can affect the operation of the transmission, resulting in internal component failure. CAUTION: Always refer to the instructions supplied with the flush and fill machine. NOTE: This is a new procedure for draining and adding transmission fluid using a suitable transmission flush and fill machine. 1. With the vehicle in PARK, position on a hoist. 2. Use a suitable flush and fill machine to change the fluid. 3. When connecting the flush and fill machine, connect the machine to the fluid cooler tube after the fluid cooler on the cooler return tube. This will help remove any foreign material trapped in the fluid coolers. 4. Carry out the fluid exchange process. Refill 1. Use only clean automatic transmission fluid. 2. Once the fluid exchange has been completed, disconnect the flush and fill machine. Reconnect any disconnected fluid cooler tubes. 3. Lower the vehicle. 4. With the engine running and the transmission at normal operating temperature 66-77°C (150-170°F), check and adjust the transmission fluid level and check for any leaks. If fluid is needed, add fluid in increments of 0.24 liter (0.5 pint) until the correct level is achieved (fluid should be in the cross-hatched area of the fluid level indicator). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition > Page 5227 Fluid - A/T: Service and Repair Check Fluid Level and Condition Check Fluid Level and Condition CAUTION: The vehicle should not be driven if the fluid level indicator shows the fluid below the Do Not Drive mark or internal failure could result. NOTE: Automatic transmission fluid expands when warmed. To obtain an accurate fluid level check, drive the vehicle until warmed, approximately 30 km (18.75 miles). If the vehicle has been operated for an extended period at high speeds, in city traffic, during hot weather or while pulling a trailer. the vehicle should be turned off for about 30 minutes to allow the fluid to cool before checking. NOTE: The transmission fluid level should be checked at normal operating temperatures, 66 - 77 °C (150 - 170 °F), on a level surface. The normal operating temperature can be reached after approximately 32 km (20 miles) of driving. However, you can check the fluid level without driving if the outside temperature is above 10 °C (50 °F). When the vehicle has not been driven, and the outside is above 10 °C (50 °F), the fluid level should be between the holes on the indicator. If the transmission fluid is to be checked when the fluid is at room temperature, the fluid level indicator could indicate that fluid should be added if the indicator is misread. If fluid is added at this time, an overfill condition could result when the vehicle reaches operating temperature of 66 - 77 °C (150 170 °F). 1. Drive the vehicle 30 km (18.75 miles) or until the vehicle reaches normal operating temperatures. 2. Park the vehicle on a level surface and apply the parking brake. 3. With the parking brake applied and your foot on the brake pedal, start the engine and move the range selector lever through all the gear ranges. Allow sufficient time for each gear to engage. 4. Place the range selector lever in (P) park and leave the engine running. 5. Remove the fluid level indicator and wipe it clean with a lint free cloth. 6. Install the fluid level indicator until it is fully seated into the filler tube. 7. Remove the fluid level indicator and inspect the fluid level. The fluid level should be in the designated area for normal and room temperature. High Fluid Level Fluid levels above the safe range may result in transmission failure. An overfill condition of transmission fluid may cause shift or engagement concerns and possible damage. High fluid levels can be caused by an overheating condition. A fluid level that is too high may cause the fluid to become aerated due to the churning action of the rotating internal parts. This will cause erratic control pressure, foaming, loss of fluid from the vent tube and possible transmission malfunction and/or damage. If an overfill reading is indicated drain and refill the transmission. Low Fluid Level DO NOT DRIVE the vehicle if the fluid level is below the hole at the bottom of the fluid level indicator or not on the fluid level indicator, and the outside temperatures are above 10 °C (50 °F). A low fluid level could result in poor transmission engagement, slipping, malfunction and/or damage. This could also indicate a leak in one of the transmission seals or gaskets. Adding Fluid Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > A/T Fluid Level Check and Condition > Page 5228 CAUTION: The use of any other type of transmission fluid than specified could result in transmission malfunction and/or damage. An overfill condition of transmission fluid may cause shift or engagement concerns and possible damage. Before adding fluid be sure that the correct type is being used. If fluid needs to be added, add fluid in 0.25 L (1/2 pint) increments through the filler tube. Do not overfill the fluid. Fluid Condition Check 1. Check the fluid level. 2. Observe the color and the odor. The color under normal circumstances should be dark reddish, not brown or black. 3. Hold the fluid level indicator over a white facial tissue and allow the fluid to drip onto the facial tissue and examine the stain. 4. If evidence of solid material is found, the transmission fluid pan should be removed for further inspection. 5. If the stain is a foamy pink color, this may indicate coolant in the transmission. The engine cooling system should also be inspected at this time. 6. If fluid contamination or transmission failure is confirmed by the sediment in the bottom of the transmission fluid pan, the transmission must be disassembled and completely cleaned. This includes the torque converter and cooler lines. 7. Carry out diagnostic checks and adjustments. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 01-22-3 > Nov > 01 > A/T Buzzing Noise When Torque Converter Engaged Fluid Filter - A/T: Customer Interest A/T - Buzzing Noise When Torque Converter Engaged Article No. 01-22-3 11/12/01 ^ NOISE - BUZZING NOISE FROM THE TRANSMISSION WHEN THE TORQUE CONVERTER IS ENGAGED - VEHICLES PRODUCED 11/15/2000 THROUGH 11/11/2001 EQUIPPED WITH 4.6L ENGINE AND 5R55W TRANSMISSION ONLY ^ TRANSMISSION - 5R55W - BUZZING NOISE FROM THE TRANSMISSION WHEN THE TORQUE CONVERTER IS ENGAGED - VEHICLES PRODUCED 11/15/2000 THROUGH 11/11/2001 EQUIPPED WITH 4.6L ENGINE ONLY FORD: 2002 EXPLORER MERCURY: 2002 MOUNTAINEER ISSUE Some vehicles built prior to 11/11/2001 equipped with 5R55W and 4.6L engine, may exhibit a buzzing noise when the torque converter is engaged and the transmission fluid temperature is between 38-66°C (100-150 °F). This may be caused by a high velocity of fluid flow in the Main Control. ACTION Verity that the condition exists using the procedure listed. If the conditions described are verified, the Main Control will need to be replaced. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE THIS ARTICLE DOES NOT APPLY TO ANY OTHER CONDITIONS OR COMPONENTS THAT MAY CAUSE SIMILAR SYMPTOMS. 1. To verity that the condition exists with the vehicle, first connect a tachometer to the engine if the vehicle is not already equipped. 2. Install an NGS or equivalent and monitor the Transmission Fluid Temperature (TFT). 3. Start the engine and drive the vehicle. 4. When the TFT reaches 38°C (100 °F), maintain a constant speed of about 80 km/h (50 mph) to engage the converter. Tap the brake pedal with the left foot. Engine RPM should increase when the brake pedal has been tapped, and decrease after about five seconds after the pedal is released. 5. Maintaining a constant vehicle speed, allow the torque converter to re-engage. 6. Listen for the Torque Converter Clutch buzzing noise. Is the noise present? ^ If yes, continue with the verification. ^ If no, follow normal diagnosis as listed in the Workshop Manual, the Main Control is not the problem. 7. Continue to bring the transmission to operating temperature above 66°C (150°F). This may be accomplished by driving the vehicle for 15 to 20 minutes. 8. After normal operating temperature is reached, maintain a constant speed of about 80 km/h (50 mph) to engage the converter. Tap the brake pedal with the left foot. Engine RPM should increase when the brake pedal has been tapped, and decrease after about five seconds after the pedal is released. 9. Maintaining a constant vehicle speed, allow the torque converter to re-engage. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 01-22-3 > Nov > 01 > A/T Buzzing Noise When Torque Converter Engaged > Page 5237 10. Listen for the Torque Converter Clutch buzzing noise. Has the noise disappeared? ^ If yes, continue. ^ If no, follow normal diagnosis as listed in the Workshop Manuals, the Main Control is not the problem. 11. If the condition exists, drain the transmission fluid from the pan. NOTE AN IN-LINE SERVICE FILTER IS NOT REQUIRED TO BE ADDED OR REPLACED FOR THIS ARTICLE. 12. Replace the Main Control 1L2Z-7A100-CA and Fluid Filter 1L2Z-7A098-AC. Follow the steps listed in the Workshop Manual, In-Vehicle Service, Main Control Valve Body, to remove and replace. 13. Verify the condition has been corrected. 14. Clear all DTCs. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 012203A Verify Conditions And 2.6 Hrs. Replace Transmission Main Control DEALER CODING CONDITION BASIC PART NO. CODE 7A100 42 OASIS CODES: 504000, 702000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 01-20-7 > Oct > 01 > A/T 5R55W Ticking Noise Fluid Filter - A/T: Customer Interest A/T - 5R55W Ticking Noise Article No. 01-20-7 10/15/01 ^ NOISE -"TICK" NOISE FROM TRANSMISSION FRONT OR INTERMEDIATE SERVO COVER AREA - VEHICLES EQUIPPED WITH 5R55W TRANSMISSION - VEHICLES PRODUCED PRIOR TO 9/6/2001 ^ TRANSMISSION - 5R55W -"TICK" NOISE FROM TRANSMISSION FRONT OR INTERMEDIATE SERVO COVER AREA - VEHICLES PRODUCED PRIOR TO 9/6/2001 FORD: 2002 EXPLORER MERCURY: 2002 MOUNTAINEER ISSUE Some vehicles produced before 9/6/2001 equipped with the 5R55W transmission, may exhibit a tick noise emanating from the Front or Intermediate Servo Cover. This tick noise is only present at Idle in Park or Neutral. ACTION Verify that the condition exists and the noise is emanating from the Front or Intermediate Servo. If so, the Separator Plate 7Z490 or the Main Control may need to be replaced. Follow the service procedures for the repair. SERVICE PROCEDURE This TSB does not apply to any other ticking noises from transmission and vehicle components or locations. NOTE DO NOT ADD THE IN-LINE SERVICE FILTER AS LISTED IN THE WORKSHOP MANUAL. THE IN-LINE FILTER IS NOT REQUIRED TO BE ADDED FOR THIS TSB. 1. Verify that the condition exists ONLY during the following conditions: - at Idle, - while in Park and Neutral, - with the noise emanating from the Front or Intermediate Servos. 2. If the condition exists, drain the transmission fluid from the pan. 3. Remove the fluid pan and fluid pan gasket (the gasket is reusable). 4. Inspect the fluid in pan for major contamination. If major contamination is present, the Main Control (7A100) and Fluid Filter will need to be replaced. 5. If major contamination is not present, only the Main Control Separating Plate and fluid filter need to be replaced. 6. To replace ONLY the Main Control (7A100) and Fluid Filter (7A098), follow the steps listed in the Workshop Manual In-Vehicle Service, Main Control Valve Body, to remove and replace. 7. To replace ONLY the Main Control Separating Plate (7Z490) and Fluid Filter (7A098), follow the removal steps listed in the Workshop Manual In-Vehicle Service, Main Control Valve Body. 8. Once the Main Control Valve Body has been removed, rotate the body so that the separator is up and place on a clean work surface. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 01-20-7 > Oct > 01 > A/T 5R55W Ticking Noise > Page 5242 9. Remove the three screws that attach the plate to the main control, remove and discard the plate (Figure 1). 10. Make sure that the check balls are in there proper location (Figure 2). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 01-20-7 > Oct > 01 > A/T 5R55W Ticking Noise > Page 5243 11. lnstall the Special Service Tools 307-334 (2 required) on to the main control (Figure 3). 12. Install a NEW service Separator Plate, install the three (3) screws and tighten to 10 Nm (89 lb-in). Remove the Special Service Tools. 13. Reinstall the Main Control by continuing to follow the Installation steps listed in the Workshop Manual In-Vehicle Service, Main Control Valve Body. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 012007A Replace Main Control 1.8 Hrs. Valve Body And Fluid Filter 012007B Replace Main Control 1.9 Hrs. Valve Body Separator Plate And Fluid Filter DEALER CODING CONDITION BASIC PART NO. CODE 7Z490 42 OASIS CODES: 504000, 597997, 702000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 01-14-2 > Jul > 01 > A/T 5R55W Whine/Howl When Cold Fluid Filter - A/T: Customer Interest A/T - 5R55W Whine/Howl When Cold Article No. 01-14-2 07/23/01 ^ NOISE - "WHINE" OR "HOWL" NOISE FROM TRANSMISSION AT START-UP TEMPERATURES BELOW 4 C (40 F) - VEHICLES EQUIPPED WITH 5R55W TRANSMISSION PRODUCED 11/13/2000 THROUGH 8/1/2001 ONLY ^ TRANSMISSION - 5R55W - "WHINE" OR "HOWL" NOISE FROM TRANSMISSION AT START-UP - TEMPERATURES BELOW 4 C (40 F) - PRODUCED 11/13/2000 THROUGH 8/1/2001 ONLY FORD: 2002 EXPLORER MERCURY: 2002 MOUNTAINEER ISSUE Some vehicles, built prior to 8/01/2001, may exhibit a "whine" or "howl" noise during cold starts at temperatures below 4° C (40°F). This noise may be caused by the transmission fluid filter. ACTION Verify that the noise ONLY occurs during start up with ambient temperatures below 4°C (40 °F). If the noise is present only under those conditions replace the transmission fluid filter. Refer to the following Service Procedures for details. SERVICE PROCEDURE 1. Raise vehicle on a hoist. 2. Drain the fluid from the pan. 3. Remove the pan and gasket. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Filter - A/T: > 01-14-2 > Jul > 01 > A/T 5R55W Whine/Howl When Cold > Page 5248 4. Replace the original filter with the new service filter 1L2Z-7A098-AC (Figure 1). 5. Clean the pan. 6. Reinstall the fluid pan gasket and pan. Tighten the screws in a crisscross pattern to 11 N.m (8 lb-ft). 7. Add fluid and adjust to the proper level, refer to the workshop manual procedure, Fluid Level Check. 8. If the noise is still present after the fluid filter has been replaced, follow normal diagnosis for noise concerns using the Diagnosis by Symptom Charts in the Workshop Manual (Section 307-01). Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011402A Replace Transmission 1.0 Hr. Fluid Filter DEALER CODING CONDITION BASIC PART NO. CODE 7A098 42 OASIS CODES: 501000, 502000, 503000, 504000, 702000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 01-22-3 > Nov > 01 > A/T - Buzzing Noise When Torque Converter Engaged Fluid Filter - A/T: All Technical Service Bulletins A/T - Buzzing Noise When Torque Converter Engaged Article No. 01-22-3 11/12/01 ^ NOISE - BUZZING NOISE FROM THE TRANSMISSION WHEN THE TORQUE CONVERTER IS ENGAGED - VEHICLES PRODUCED 11/15/2000 THROUGH 11/11/2001 EQUIPPED WITH 4.6L ENGINE AND 5R55W TRANSMISSION ONLY ^ TRANSMISSION - 5R55W - BUZZING NOISE FROM THE TRANSMISSION WHEN THE TORQUE CONVERTER IS ENGAGED - VEHICLES PRODUCED 11/15/2000 THROUGH 11/11/2001 EQUIPPED WITH 4.6L ENGINE ONLY FORD: 2002 EXPLORER MERCURY: 2002 MOUNTAINEER ISSUE Some vehicles built prior to 11/11/2001 equipped with 5R55W and 4.6L engine, may exhibit a buzzing noise when the torque converter is engaged and the transmission fluid temperature is between 38-66°C (100-150 °F). This may be caused by a high velocity of fluid flow in the Main Control. ACTION Verity that the condition exists using the procedure listed. If the conditions described are verified, the Main Control will need to be replaced. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE THIS ARTICLE DOES NOT APPLY TO ANY OTHER CONDITIONS OR COMPONENTS THAT MAY CAUSE SIMILAR SYMPTOMS. 1. To verity that the condition exists with the vehicle, first connect a tachometer to the engine if the vehicle is not already equipped. 2. Install an NGS or equivalent and monitor the Transmission Fluid Temperature (TFT). 3. Start the engine and drive the vehicle. 4. When the TFT reaches 38°C (100 °F), maintain a constant speed of about 80 km/h (50 mph) to engage the converter. Tap the brake pedal with the left foot. Engine RPM should increase when the brake pedal has been tapped, and decrease after about five seconds after the pedal is released. 5. Maintaining a constant vehicle speed, allow the torque converter to re-engage. 6. Listen for the Torque Converter Clutch buzzing noise. Is the noise present? ^ If yes, continue with the verification. ^ If no, follow normal diagnosis as listed in the Workshop Manual, the Main Control is not the problem. 7. Continue to bring the transmission to operating temperature above 66°C (150°F). This may be accomplished by driving the vehicle for 15 to 20 minutes. 8. After normal operating temperature is reached, maintain a constant speed of about 80 km/h (50 mph) to engage the converter. Tap the brake pedal with the left foot. Engine RPM should increase when the brake pedal has been tapped, and decrease after about five seconds after the pedal is released. 9. Maintaining a constant vehicle speed, allow the torque converter to re-engage. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 01-22-3 > Nov > 01 > A/T - Buzzing Noise When Torque Converter Engaged > Page 5254 10. Listen for the Torque Converter Clutch buzzing noise. Has the noise disappeared? ^ If yes, continue. ^ If no, follow normal diagnosis as listed in the Workshop Manuals, the Main Control is not the problem. 11. If the condition exists, drain the transmission fluid from the pan. NOTE AN IN-LINE SERVICE FILTER IS NOT REQUIRED TO BE ADDED OR REPLACED FOR THIS ARTICLE. 12. Replace the Main Control 1L2Z-7A100-CA and Fluid Filter 1L2Z-7A098-AC. Follow the steps listed in the Workshop Manual, In-Vehicle Service, Main Control Valve Body, to remove and replace. 13. Verify the condition has been corrected. 14. Clear all DTCs. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 012203A Verify Conditions And 2.6 Hrs. Replace Transmission Main Control DEALER CODING CONDITION BASIC PART NO. CODE 7A100 42 OASIS CODES: 504000, 702000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 01-20-7 > Oct > 01 > A/T - 5R55W Ticking Noise Fluid Filter - A/T: All Technical Service Bulletins A/T - 5R55W Ticking Noise Article No. 01-20-7 10/15/01 ^ NOISE -"TICK" NOISE FROM TRANSMISSION FRONT OR INTERMEDIATE SERVO COVER AREA - VEHICLES EQUIPPED WITH 5R55W TRANSMISSION - VEHICLES PRODUCED PRIOR TO 9/6/2001 ^ TRANSMISSION - 5R55W -"TICK" NOISE FROM TRANSMISSION FRONT OR INTERMEDIATE SERVO COVER AREA - VEHICLES PRODUCED PRIOR TO 9/6/2001 FORD: 2002 EXPLORER MERCURY: 2002 MOUNTAINEER ISSUE Some vehicles produced before 9/6/2001 equipped with the 5R55W transmission, may exhibit a tick noise emanating from the Front or Intermediate Servo Cover. This tick noise is only present at Idle in Park or Neutral. ACTION Verify that the condition exists and the noise is emanating from the Front or Intermediate Servo. If so, the Separator Plate 7Z490 or the Main Control may need to be replaced. Follow the service procedures for the repair. SERVICE PROCEDURE This TSB does not apply to any other ticking noises from transmission and vehicle components or locations. NOTE DO NOT ADD THE IN-LINE SERVICE FILTER AS LISTED IN THE WORKSHOP MANUAL. THE IN-LINE FILTER IS NOT REQUIRED TO BE ADDED FOR THIS TSB. 1. Verify that the condition exists ONLY during the following conditions: - at Idle, - while in Park and Neutral, - with the noise emanating from the Front or Intermediate Servos. 2. If the condition exists, drain the transmission fluid from the pan. 3. Remove the fluid pan and fluid pan gasket (the gasket is reusable). 4. Inspect the fluid in pan for major contamination. If major contamination is present, the Main Control (7A100) and Fluid Filter will need to be replaced. 5. If major contamination is not present, only the Main Control Separating Plate and fluid filter need to be replaced. 6. To replace ONLY the Main Control (7A100) and Fluid Filter (7A098), follow the steps listed in the Workshop Manual In-Vehicle Service, Main Control Valve Body, to remove and replace. 7. To replace ONLY the Main Control Separating Plate (7Z490) and Fluid Filter (7A098), follow the removal steps listed in the Workshop Manual In-Vehicle Service, Main Control Valve Body. 8. Once the Main Control Valve Body has been removed, rotate the body so that the separator is up and place on a clean work surface. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 01-20-7 > Oct > 01 > A/T - 5R55W Ticking Noise > Page 5259 9. Remove the three screws that attach the plate to the main control, remove and discard the plate (Figure 1). 10. Make sure that the check balls are in there proper location (Figure 2). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 01-20-7 > Oct > 01 > A/T - 5R55W Ticking Noise > Page 5260 11. lnstall the Special Service Tools 307-334 (2 required) on to the main control (Figure 3). 12. Install a NEW service Separator Plate, install the three (3) screws and tighten to 10 Nm (89 lb-in). Remove the Special Service Tools. 13. Reinstall the Main Control by continuing to follow the Installation steps listed in the Workshop Manual In-Vehicle Service, Main Control Valve Body. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 012007A Replace Main Control 1.8 Hrs. Valve Body And Fluid Filter 012007B Replace Main Control 1.9 Hrs. Valve Body Separator Plate And Fluid Filter DEALER CODING CONDITION BASIC PART NO. CODE 7Z490 42 OASIS CODES: 504000, 597997, 702000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 01-14-2 > Jul > 01 > A/T - 5R55W Whine/Howl When Cold Fluid Filter - A/T: All Technical Service Bulletins A/T - 5R55W Whine/Howl When Cold Article No. 01-14-2 07/23/01 ^ NOISE - "WHINE" OR "HOWL" NOISE FROM TRANSMISSION AT START-UP TEMPERATURES BELOW 4 C (40 F) - VEHICLES EQUIPPED WITH 5R55W TRANSMISSION PRODUCED 11/13/2000 THROUGH 8/1/2001 ONLY ^ TRANSMISSION - 5R55W - "WHINE" OR "HOWL" NOISE FROM TRANSMISSION AT START-UP - TEMPERATURES BELOW 4 C (40 F) - PRODUCED 11/13/2000 THROUGH 8/1/2001 ONLY FORD: 2002 EXPLORER MERCURY: 2002 MOUNTAINEER ISSUE Some vehicles, built prior to 8/01/2001, may exhibit a "whine" or "howl" noise during cold starts at temperatures below 4° C (40°F). This noise may be caused by the transmission fluid filter. ACTION Verify that the noise ONLY occurs during start up with ambient temperatures below 4°C (40 °F). If the noise is present only under those conditions replace the transmission fluid filter. Refer to the following Service Procedures for details. SERVICE PROCEDURE 1. Raise vehicle on a hoist. 2. Drain the fluid from the pan. 3. Remove the pan and gasket. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 01-14-2 > Jul > 01 > A/T - 5R55W Whine/Howl When Cold > Page 5265 4. Replace the original filter with the new service filter 1L2Z-7A098-AC (Figure 1). 5. Clean the pan. 6. Reinstall the fluid pan gasket and pan. Tighten the screws in a crisscross pattern to 11 N.m (8 lb-ft). 7. Add fluid and adjust to the proper level, refer to the workshop manual procedure, Fluid Level Check. 8. If the noise is still present after the fluid filter has been replaced, follow normal diagnosis for noise concerns using the Diagnosis by Symptom Charts in the Workshop Manual (Section 307-01). Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011402A Replace Transmission 1.0 Hr. Fluid Filter DEALER CODING CONDITION BASIC PART NO. CODE 7A098 42 OASIS CODES: 501000, 502000, 503000, 504000, 702000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Page 5266 Fluid Filter - A/T: Specifications Transmission fluid filter screws .................................................................................................................................................... 8-11 Nm (71-97 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Page 5267 Fluid Filter - A/T: Service and Repair Fluid Pan, Gasket and Filter Removal 1. Position the vehicle on a hoist. Place in NEUTRAL. 2. NOTE: If equipped, the transmission servo heat shield must be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. If equipped, loosen the nut and position the heat shield out of the way. 3. Place a drain pan under the transmission fluid pan. 4. Drain transmission fluid. - Remove all the transmission fluid pan bolts except for two in the front. Loosen the two front transmission fluid pan screws. Pry the rear of the transmission fluid pan down and allow fluid to drain. After fluid is drained, remove the front two transmission fluid pan screws. 5. Remove the transmission fluid pan. 1 Remove the transmission fluid pan. 2 Remove and discard the transmission fluid pan gasket. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Page 5268 6. Remove and discard the transmission fluid filter. 1 Remove the transmission fluid filter screw. 2 Remove the transmission fluid filter. 7. Clean and inspect the transmission fluid pan and magnet. Clean all mating surfaces. 8. Flush the transmission fluid cooler and transmission fluid cooler lines. Installation 1. CAUTION: Lubricate fluid filter O-ring seals with clean automatic transmission fluid or they can be damaged if; Lube and install new O-ring seals onto the transmission fluid filter. Install a new transmission fluid filter. Position the transmission fluid filter on the main control valve body. 2. Install the transmission fluid filter. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Page 5269 3. Position the oil pan magnet in the transmission fluid pan. 4. Install the transmission fluid pan. 1 Position a new transmission fluid pan gasket on the transmission fluid pan. 2 Install and align the transmission fluid pan. - Loosely install the transmission fluid pan screws. 5. Tighten the transmission fluid pan screws. - Tighten the transmission fluid pan screws in a crisscross sequence. 6. If equipped, position the servo heat shield over the servos and clip it to the pan rail. 7. Lower the vehicle. 8. Apply the park brake, and start the engine. 9. NOTE: When filling a dry transmission and converter, start with a minimum of 3.7 liters (4 quarts). Fill transmission with clean automatic transmission fluid to the correct fluid level and check for correct transmission operation. 10. Move the range selector lever through all the gears. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Page 5270 11. Recheck the transmission fluid level. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 01-10-2 > May > 01 > A/T - 5R55W Cooler Line Fluid Leak Fluid Line/Hose: Customer Interest A/T - 5R55W Cooler Line Fluid Leak Article No. 01-10-2 05/28/01 TRANSMISSION - 5R55W - FLUID LEAK FROM TRANSMISSION COOLER LINES AT TRANSMISSION CASE CONNECTION - EXPLORER/MOUNTAINEER 4-DOOR VEHICLES BUILT 11/13/2000 THROUGH 4/2/2001 ONLY FORD: 2002 EXPLORER MERCURY: 2002 MOUNTAINEER ISSUE Some 2002 Explorer/Mountaineer 4-door vehicles built 11/13/2000 through 4/2/2001 equipped with the 5R55W transmission may exhibit a fluid leak at the transmission cooler line-to-transmission case connection. This may be caused by contamination on the cooler tube between the tube nut and flare, contamination on the tube nut threads or improper installation torque. ACTION If fluid is leaking from the cooler lines at the transmission, the cooler line tube nuts and lines will need to be disconnected, cleaned and a service 0-ring installed into the case fitting. Refer to the following Service Procedure for details. SERVICE PROCEDURE Use the following service procedure to repair the cooler line leak. 1. Remove the cooler lines from the transmission (Figure 1). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 01-10-2 > May > 01 > A/T - 5R55W Cooler Line Fluid Leak > Page 5279 2. Clean the cooler tube nut threads, clean the cooler lines at the flare and the cooler line surfaces between the line and the cooler tube nuts (Figure 2). 3. Install the service 0-rings (W702015-S300) as shown in Figure 3. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 01-10-2 > May > 01 > A/T - 5R55W Cooler Line Fluid Leak > Page 5280 4. Reinstall the cooler lines into the case and tighten the cooler tube nuts to 30 N.m (22 lb-ft) (Figure 4). 5. Clean all residual fluid from around the cooler line fittings. 6. Start vehicle and check for leaks. 7. Verify fluid level (refer to the appropriate Workshop Manual, Section 307-01) for proper procedure. Add fluid as necessary. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011002A Install 0-Rings On 1.0 Hr. Transmission Cooler Lines (Includes Time To Disconnect, Clean And Install 0-Rings) DEALER CODING CONDITION BASIC PART NO. CODE 7D273 42 OASIS CODES: 501000, 504000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Line/Hose: > 01-10-2 > May > 01 > A/T - 5R55W Cooler Line Fluid Leak Fluid Line/Hose: All Technical Service Bulletins A/T - 5R55W Cooler Line Fluid Leak Article No. 01-10-2 05/28/01 TRANSMISSION - 5R55W - FLUID LEAK FROM TRANSMISSION COOLER LINES AT TRANSMISSION CASE CONNECTION - EXPLORER/MOUNTAINEER 4-DOOR VEHICLES BUILT 11/13/2000 THROUGH 4/2/2001 ONLY FORD: 2002 EXPLORER MERCURY: 2002 MOUNTAINEER ISSUE Some 2002 Explorer/Mountaineer 4-door vehicles built 11/13/2000 through 4/2/2001 equipped with the 5R55W transmission may exhibit a fluid leak at the transmission cooler line-to-transmission case connection. This may be caused by contamination on the cooler tube between the tube nut and flare, contamination on the tube nut threads or improper installation torque. ACTION If fluid is leaking from the cooler lines at the transmission, the cooler line tube nuts and lines will need to be disconnected, cleaned and a service 0-ring installed into the case fitting. Refer to the following Service Procedure for details. SERVICE PROCEDURE Use the following service procedure to repair the cooler line leak. 1. Remove the cooler lines from the transmission (Figure 1). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Line/Hose: > 01-10-2 > May > 01 > A/T - 5R55W Cooler Line Fluid Leak > Page 5286 2. Clean the cooler tube nut threads, clean the cooler lines at the flare and the cooler line surfaces between the line and the cooler tube nuts (Figure 2). 3. Install the service 0-rings (W702015-S300) as shown in Figure 3. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Line/Hose: > 01-10-2 > May > 01 > A/T - 5R55W Cooler Line Fluid Leak > Page 5287 4. Reinstall the cooler lines into the case and tighten the cooler tube nuts to 30 N.m (22 lb-ft) (Figure 4). 5. Clean all residual fluid from around the cooler line fittings. 6. Start vehicle and check for leaks. 7. Verify fluid level (refer to the appropriate Workshop Manual, Section 307-01) for proper procedure. Add fluid as necessary. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011002A Install 0-Rings On 1.0 Hr. Transmission Cooler Lines (Includes Time To Disconnect, Clean And Install 0-Rings) DEALER CODING CONDITION BASIC PART NO. CODE 7D273 42 OASIS CODES: 501000, 504000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Line/Hose: > 03E05 > Jan > 04 > Recall - EVAP Fresh Air Hose Defect Technical Service Bulletin # 03E05 Date: 040101 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Line/Hose: > 03E05 > Jan > 04 > Recall - EVAP Fresh Air Hose Defect > Page 5293 Attachment I - Administrative Information Emissions Recall 03E05 Certain 2002 and 2003 MY Explorer Sport Trac Vehicles Evaporative Emissions Canister Fresh Air Inlet Hose Connector Replacement OASIS ACTIVATED? Yes FSA VIN LIST ACTIVATED? Yes NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states provinces and countries. Accordingly you must limit the use of this listing to the follow-up necessary to complete this action. STOCK VEHICLES Correct all affected stock vehicles before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the owner a copy of the Customer Notification Letter and schedule a service date. ^ Also correct other affected vehicles identified in OASIS which are brought to your dealership. RELATED DAMAGE Related damage claims are not approved for this program. ADDITIONAL LABOR TIME Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Line/Hose: > 03E05 > Jan > 04 > Recall - EVAP Fresh Air Hose Defect > Page 5294 ^ This repair will require no additional labor time to complete. Claims submitted with "MT" labor will not be accepted for reimbursement. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition call the Special Service Support Center. OWNER REFUNDS ^ Ford Motor Company will only refund owner-paid repairs related to this recall that were made before the date of the Customer Notification Letter (or after the date of the letter if an emergency repair was made away from the servicing dealer). Refund claims that include other non-covered repairs or those judged by Ford to be excessive will not be accepted for reimbursement. ^ This recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close out the VIN for this recall. ^ Refund Claiming Information. (Submit on separate repair line) - Program Code: 03E05 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hr. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION The Evaporative Emissions Fresh Air Inlet Hose Elbow Assembly (9S327) will not be direct shipped for this recall. Order this part through the normal order processing channels. ADDITIONAL PARTS REQUIREMENTS / ORDERING INFORMATION NOTE: This only applies to vehicles that arrive at the dealership with the fresh air inlet hose disconnected. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Line/Hose: > 03E05 > Jan > 04 > Recall - EVAP Fresh Air Hose Defect > Page 5295 Dealers must call the Special Service Support Center prior to the repair, if replacement of the EVAP canister assembly is required. Inform the representative you are calling in regard to Emissions Recall 03E05. Be prepared to provide the information shown. ^ Vehicle Identification Number ^ Dealership P/A code Dealership address The DOR/COR for this program is 50311. This number identifies parts ordered for this recall through the Special Service Support Center. DEALER PRICE For latest prices refer to DOES II. PARTS RETENTION AND RETURN Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures. EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information OVERVIEW This document details the procedure for replacing the fresh air inlet hose connector with an elbow assembly for the evaporative emissions (EVAP) canister. NOTE! Less than 15% of the affected vehicles may arrive at the dealership with the fresh air inlet hose disconnected from the wheel well splash shield. The evaporative emissions canister assembly must be replaced on these vehicles. Call the Special Service Support Center if replacement of the EVAP canister is required. See Evaporative Emissions Canister Assembly Replacement in this document for replacement procedures. DO NOT REPLACE the evaporative emissions canister if the vehicle arrives with the hose attached to the wheel well splash shield. FRESH AIR INLET HOSE CONNECTOR REPLACEMENT 1. Disconnect the EVAP canister fresh air inlet hose connector from the opening in the driver-side rear wheel well splash shield. See Figure 1. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Line/Hose: > 03E05 > Jan > 04 > Recall - EVAP Fresh Air Hose Defect > Page 5296 2. Measure 12.7 mm (0.5 in.) from the bulge in the fresh air inlet hose and, using an appropriate hose cutter, cut the end of the hose off and discard. Make sure no debris falls into the hose. See Figure 2. 3. Install the new fresh air inlet hose elbow assembly into the hose and position it through the splash shield opening. 4. CAUTION: A restriction of air flow in the fresh air inlet hose may result in a slow fuel fill condition. Make sure the fresh air inlet hose is not pinched after tie strap installation. Secure the fresh air inlet hose to the fuel tank breather tube with a tie strap as indicated. See Figure 3. 5. Proceed to Authorized Modifications Label and Proof of Correction Certificate in this document. EVAPORATIVE EMISSIONS CANISTER ASSEMBLY REPLACEMENT NOTE! Call the Special Service Support Center if replacement of the EVAP canister is required. NOTE! Perform this procedure only if the vehicle arrived at the dealership with the fresh air inlet hose disconnected from the wheel well splash shield 1. Disconnect the battery negative cable. 2. Lower and remove the spare tire. 3. Raise the vehicle on a hoist. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Line/Hose: > 03E05 > Jan > 04 > Recall - EVAP Fresh Air Hose Defect > Page 5297 4. Remove the five (5) EVAP canister assembly mounting bolts. See Figure 4. 5. Position the EVAP canister so you can access and disconnect the vapor hose from the passenger side of the EVAP canister, then the vent solenoid electrical connector, the wiring harness pin-type retainer and the vapor hose from the driver side of the EVAP canister. Once all the items are disconnected, remove the EVAP canister from the vehicle. See Figure 5. 6. Connect the vapor hose, wiring harness pin-type retainer and the vent solenoid electrical connector to the driver side of the new EVAP canister. Then connect the vapor hose to the passenger side of new EVAP canister. 7. Install the five (5) canister assembly mounting bolts. Tighten the bolts to 10 Nm (89 lb-in). 8. Lower the vehicle. 9. Position and raise the spare tire. 10. Connect the battery negative cable. 11. Perform an Evaporative Emissions System Leak Test as follows: a) CAUTION: The evaporative emission system must not be pressurized to more than 3.48 kPa (1.03 in Hg) or damage to the evaporative Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Line/Hose: > 03E05 > Jan > 04 > Recall - EVAP Fresh Air Hose Defect > Page 5298 emission system may occur. Connect the Evaporative Emission System Leak Tester 310-F007 (134-00056 or equivalent) to the evaporative test port. b) NOTE: The ignition switch must be in the Key ON/Engine OFF position. c) Using WDS, NGS or equivalent, apply 12 volts to the canister vent solenoid. d) Pressurize the evaporative emissions system to 3.48 kPa (1.03 inHg). e) Monitor the system for two (2) minutes. If pressure falls below 2.0 kPa (0.6 inHg), the system has failed the leak test. f) Repair any leaks as necessary. (NOTE: Any repairs not related directly to the EVAP canister assembly replacement are not covered by this program.) g) Repeat the Evaporative Emissions System Leak Test until the system remains above 2.0 kPa (0.6 inHg) after the last test period. 12. Proceed to Authorized Modifications Label and Proof of Correction Certificate in this document. AUTHORIZED MODIFICATIONS LABEL AND PROOF OF CORRECTION CERTIFICATE 1. Obtain and prepare an Authorized Modifications Label. Write your P&A; code, date of repair, the program type and number, and either "EVAP CANISTER FRESH AIR INLET HOSE MODIFIED" or "EVAP CANISTER FRESH AIR INLET HOSE MODIFIED AND EVAP CANISTER REPLACED" in the space provided. See Figure 6. 2. Apply the label to a clean area adjacent to the Vehicle Emissions Control Information (VECI) label, then cover it with a clear plastic decal shield. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Line/Hose: > 03E05 > Jan > 04 > Recall - EVAP Fresh Air Hose Defect > Page 5299 3. Provide California and Massachusetts owners with a "Vehicle Emission Recall - Proof of Correction" certificate. See Figure 7. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Line/Hose: > 03E05 > Jan > 04 > Recall - EVAP Fresh Air Hose Defect > Page 5300 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Line/Hose: > 03E05 > Jan > 04 > Recall - EVAP Fresh Air Hose Defect > Page 5301 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Line/Hose: > 03E05 > Jan > 04 > Recall - EVAP Fresh Air Hose Defect > Page 5302 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Line/Hose: > 03E05 > Jan > 04 > Recall - EVAP Fresh Air Hose Defect > Page 5303 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Line/Hose: > 03E05 > Jan > 04 > Recall - EVAP Fresh Air Hose Defect > Page 5304 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Page 5305 Fluid Line/Hose: Specifications Transmission cooler lines to case connectors ................................................................................................................................. 35-43 Nm (26-32 ft. lbs.) Transmission cooler line nut .......................................................................................................................................................... 24-31 Nm (18-23 ft. lbs.) Transmission cooler lines bracket bolts .................................................................................................................................... 3.1-4.3 Nm (28-38 inch lbs.) Transmission fluid cooler tube-to-case fitting ................................................................................................................................ 24-31 Nm (18-23 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > A/T - 5R44E/5R55E Part Level Change/Compatibility Fluid Pan: Technical Service Bulletins A/T - 5R44E/5R55E Part Level Change/Compatibility TSB 06-24-13 11/20/06 5R44E / 5R55E SERVICE PART LEVEL CHANGE / COMPATIBILITY FORD: 1997 Aerostar 1997-2001 Explorer 1997-2007 Ranger 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac MERCURY: 1998-2001 Mountaineer ISSUE Some vehicles equipped with a 5R44E or 5R55E automatic transmission may require repair of the transmission. This TSB is being published as informational only in order to avoid mix I match of incorrect service parts which will cause a fluid leak. Beginning with 8/29/2006 production, the 5R44E or 5R55E automatic transmission will have a new transmission case, fluid pan, a REUSABLE fluid pan gasket and new fluid pan screws. ACTION Follow the Service Tips. SERVICE TIPS NOTE DO NOT MIX AND MATCH PARTS OR LEAKAGE WILL OCCUR. NOTE THE NEW PAN GASKET IS NOT INCLUDED IN THE GASKET AND SEAL KIT. IT CAN ONLY BE ORDERED SEPARATELY. The 5R44E / 5R55E transmission pan gasket has been redesigned to be reusable if it is removed for a non-leak related transmission service concern. The gasket should be inspected for damage and cleaned, along with the mating surfaces, before reuse. The case and fluid pan rails have been redesigned to properly mate with the new gasket to eliminate fluid leaks. The new case, pan, and gasket maybe used to service past model transmissions from 1997. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > A/T - 5R44E/5R55E Part Level Change/Compatibility > Page 5310 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > A/T - 5R44E/5R55E Part Level Change/Compatibility > Page 5311 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > A/T - 5R44E/5R55E Part Level Change/Compatibility > Page 5312 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > A/T - 5R44E/5R55E Part Level Change/Compatibility > Page 5313 For 1997-2007 (early production) 4R44E I 5R44E and 5R55E when servicing the fluid pan gasket (7A191), the fluid pan (7A194) or the case (7005) do not mix and match old level and new level parts. The old level gasket, refer to Figure 3 (7A191) will be continued for past model applications. If replacing the older design level case, refer to Figure 1 (7005) and/or old lever fluid pan, refer to Figure 2 (7A194), ALL new components must be used. This includes the case (7005), refer to Figure 4, fluid pan (7A194), refer to Figure 5, fluid pan gasket (7A191), refer to Figure 6 and pan screws (W500212) (new torque specification - 7 lb-ft (10 N.m) refer to Figure 7. For correct part numbers refer to your parts catalogue. WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > Page 5314 Fluid Pan: Service and Repair "For information regarding this component please refer to fluid filter service and repair" Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications Fluid Pump: Specifications Fluid pump screws ............................................................................................................................... .......................................... 22-28 Nm (16-21 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Service and Repair Parking Pawl: Service and Repair Park System Removal 1. Position the vehicle on a hoist. Place in NEUTRAL. 2. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts, either soft or firm, and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. Loosen the nut and position the heat shield out of the way. 4. Disconnect the shift cable from the manual control lever. 5. Disconnect the digital Transmission Range (TR) sensor electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Service and Repair > Page 5321 6. Remove the manual control outer lever nut and manual control outer lever. 7. Loosen the screws on the digital TR sensor. 8. Remove the transmission fluid pan. 1 Remove the transmission fluid pan. 2 Remove and discard the transmission fluid pan gasket. 9. Remove the transmission fluid filter. 1 Remove the transmission fluid filter screw. 2 Remove the transmission fluid filter. 10. Remove wire loom guide and protector. - Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Service and Repair > Page 5322 11. Disconnect the solenoid electrical connectors. 1 Disconnect shift solenoids SSB and SSD electrical connectors. 2 Disconnect the Torque Converter Clutch (TCC) solenoid electrical connector. 3 Disconnect the Electronic Pressure Control (EPC) solenoid electrical connector. 12. CAUTION: The TCC solenoid and converter modulator valve can pop out of their bore. This may damage the solenoid or converter modulator valve. Remove the EPC, SSB, and SSD solenoids. 1 Remove the wire harness. 2 Remove the solenoid clamp screws. 3 Remove the solenoid clamp. 4 Remove the EPC, SSB and SSD solenoids. 13. CAUTION: Do not pry on the other wires or damage to the connector case surface can result. Disconnect the Turbine Shaft Speed (TSS) sensor electrical connector from the transmission case (16-pin) electrical connector. 1 Disconnect the TSS sensor electrical connector. 2 Remove the TSS sensor wire locator Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Service and Repair > Page 5323 14. CAUTION: Do not overstretch the retaining spring. Remove the transmission case (16-pin) electrical connector retaining spring. 15. CAUTION: Do not damage the connector or harness. Remove the transmission case (16-pin) electrical connector. Compress the tabs on the connector. - Push the connector out of the transmission case. 16. Remove the manual control valve detent lever span. 1 Remove the screw. 2 Remove the spring. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Service and Repair > Page 5324 17. CAUTION: To avoid damage, make sure the wrench does not strike the manual valve inner lever pin. Remove the manual valve inner lever nut. 18. Remove the manual valve inner lever and parking lever actuating rod. 19. NOTE: To maintain initial driveshaft balance, mark the rear driveshaft yoke and axle flange so they can be installed in their original alignment. Mark the rear driveshaft. 20. Remove the rear driveshaft. 1 Remove the bolts. 2 Remove the rear driveshaft. 21. If equipped, remove the transfer case. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Service and Repair > Page 5325 22. NOTE: If damage is found to the parking gear, the transmission must be removed and disassembled. NOTE: The parking pawl, parking pawl return spring and parking pawl shaft may fall out during removal of the extension housing. Remove the extension housing and discard the extension housing gasket. 23. Inspect the parking pawl, parking pawl return spring and the parking pawl shaft. - Install new components if required. Installation 1. CAUTION: Make sure the parking lever actuating rod is correctly seated into the case parking rod guide cup. Verify that the output shaft is locked in the PARK position. Align the flats of the manual valve inner lever with the flats on the manual control lever shaft. Install the manual valve inner lever and parking lever actuating rod onto the manual control lever shaft. 2. CAUTION: Do not bend the manual valve inner lever pin. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Service and Repair > Page 5326 Install the manual valve inner lever nut. 3. Rotate the manual lever into the NEUTRAL position, and install the manual valve detent spring. 4. Clean the extension housing and install a new extension housing gasket. Make sure that the parking pawl, spring and shaft is correctly installed. 5. CAUTION: Make sure the parking lever actuating rod is correctly seated into the case parking rod guide cup. Install the extension housing. 1 Position the extension housing. 2 Install the extension housing screws. 3 Install the extension housing stud. 6. If equipped, install the transfer case. 7. NOTE: Align the driveshaft with the marks made during removal to make sure balance is correct. Install the rear driveshaft bolts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Service and Repair > Page 5327 8. NOTE: Make sure the tab is in the LOCKED position. NOTE: Install new O-ring seals on the transmission case (16-pin) electrical connector. Install the transmission case (16-pin) electrical connector. Lubricate the transmission case (16-pin) electrical connector O-ring seals with petroleum jelly. 9. Press the transmission case (16-pin) electrical connector through the case until a click is heard. 10. CAUTION: Align the slot on the TSS sensor electrical connector with the slot in the (16-pin) case connector. Install the TSS sensor wire. 1 Install the TSS sensor wire into (16-pin) electrical connector. 2 Install the TSS sensor wire into locator. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Service and Repair > Page 5328 11. CAUTION: Do not overstretch the retaining spring. Install the transmission case (16-pin) electrical connector retaining spring. 12. Install the EPC, SSD and SSB solenoids. 13. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 204 plug. Install the solenoid clamp. 1 Position the solenoid clamp on the main control valve body. 2 Install the solenoid clamp screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Service and Repair > Page 5329 14. Connect the TCC, SSD, SSB and EPC solenoid electrical connectors. 15. CAUTION: Excessive pressure can break the retaining pins. Install the wire loom guide and protector. Align the retaining pins to the holes in the solenoid clamps and gently press in the wire loom guide and protector. 16. Install the transmission fluid filter. 17. Install the transmission fluid pan. 1 Install a new transmission fluid pan gasket on the transmission fluid pan. 2 Install and align the transmission fluid pan. - Loosely install the transmission fluid pan screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Service and Repair > Page 5330 18. Tighten the transmission fluid pan screws. - Tighten the transmission fluid pan screws in a crisscross sequence. 19. CAUTION: Tightening one screw before tightening the other can cause the sensor to bind or become damaged. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence. 20. Install the manual control outer lever and nut. 21. Connect the digital Transmission Range (TR) sensor electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Service and Repair > Page 5331 22. Connect the shift cable to the manual control lever. 23. If equipped, position the servo heat shield over the servos and clip it to the pan rail. 24. Lower the vehicle. 25. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts, either soft or firm, and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. 26. Fill transmission to correct fluid level and check for correct transmission operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > Customer Interest for Planetary Gears: > 02-22-2 > Nov > 02 > A/T - 5R55E 1st/2nd Gear Whining Noise Planetary Gears: Customer Interest A/T - 5R55E 1st/2nd Gear Whining Noise Article No. 02-22-2 11/11/02 ^ NOISE - GEAR WHINE NOISE IN 1ST AND 2ND GEAR ONLY - VEHICLES EQUIPPED WITH 5R55E TRANSMISSION AND 4.0L ENGINE ONLY ^ TRANSMISSION - 5R55E - GEAR WHINE NOISE IN 1ST AND 2ND GEAR ONLY - VEHICLES EQUIPPED WITH 4.0L ENGINE ONLY FORD: 2001-2003 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER ISSUE Some 2001-2003 Rangers, 2001-2003 Explorer Sport/Sport Trac, built prior to 10/18/2002, equipped with a 5R55E automatic transmission and 4.0L engine, may exhibit a gear whine type of noise in 1st and 2nd gear ONLY. This may be caused by the Reverse and Forward Planetary assemblies and/or the driveshaft. ACTION Verify that only these conditions exist and no DTCs are present. If other conditions are present and DTCs exist they must be diagnosed and serviced first. Once all other conditions are serviced and only the 1st and 2nd gear whine are still present, refer to the following Service Procedure. Using the chart provided, select the parts that need to be replaced. NOTE IF PLANETARIES ARE LISTED, BOTH MUST BE REPLACED. SERVICE PROCEDURE Gear Whine Service Procedure 1. Determine whether the driveshaft only, planetaries only or both driveshaft and planetaries need to be replaced, refer to Application and Component replacement chart shown. 2. If just the driveshaft needs to be replaced follow the procedures as listed in the appropriate Workshop Manual section for driveshaft removal/replacement. 3. If the planetaries need to be replaced, using the appropriate model and year Workshop Manual, Section 307-01, Transmission Removal procedures, remove the transmission. 4. Discard the driveshaft ONLY if being replaced. Refer to application and component replacement chart. NOTE REPLACEMENT OF THE EXTENSION HOUSING SEAL AND BUSHING ARE NOT REQUIRED. DO NOT DISASSEMBLE BEYOND THE REVERSE PLANETARY. ALL SUBASSEMBLY STEPS ARE NOT REQUIRED FOR THIS PROCEDURE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > Customer Interest for Planetary Gears: > 02-22-2 > Nov > 02 > A/T - 5R55E 1st/2nd Gear Whining Noise > Page 5340 NOTE BOTH PLANETARIES MUST BE REPLACED OR THE REPAIR MAY NOT BE EFFECTIVE. 5. Using the Transmission Disassembly procedures remove the Forward Planetary Assembly (7A398) and the Reverse Planetary Assembly (7D006) and discard. Do not disassemble beyond the Reverse Planetary assembly. 6. Using the appropriate Transmission Assembly procedures, assemble the transmission and install BOTH NEW service Reverse Planetary Assembly (XL2Z-7D006-AA) and a new service Forward Planetary Assembly (XL2Z-7A398-AA). 7. Using the appropriate model and year Workshop Manual, Section 307-01, Transmission Installation procedures, install transmission. 8. If being replaced, Install the NEW service driveshaft 2L2Z-4602-AA as required for the appropriate application listed. 9. Verify repair. Clear DTCs. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 022202A Replace Transmission 5.5 Hrs. Forward And Reverse Planetary Assemblies (Includes Time To Remove And Install Transmission 5R55E) 2001-2003 Explorer Sport/Sport Trac And Ranger 4.0L 4X2 022202B Replace Transmission 7.0 Hrs. Forward And Reverse Planetary Assemblies (Includes Time To Remove And Install Transmission 5R55E) 2001-2003 Explorer Sport/Sport Trac And Ranger 4.0L 4X4 022202C Replace Driveshaft 0.4 Hr. Only 2002-2003 Explorer Sport Trac 4x2 DEALER CODING CONDITION BASIC PART NO. CODE 7A398 42 OASIS CODES: 501000 502000, 504000, 597997, 703200, 703400 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > Customer Interest for Planetary Gears: > 02-22-2 > Nov > 02 > A/T - 5R55E 1st/2nd Gear Whining Noise > Page 5341 DISCLAIMER Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Planetary Gears: > 02-22-2 > Nov > 02 > A/T - 5R55E 1st/2nd Gear Whining Noise Planetary Gears: All Technical Service Bulletins A/T - 5R55E 1st/2nd Gear Whining Noise Article No. 02-22-2 11/11/02 ^ NOISE - GEAR WHINE NOISE IN 1ST AND 2ND GEAR ONLY - VEHICLES EQUIPPED WITH 5R55E TRANSMISSION AND 4.0L ENGINE ONLY ^ TRANSMISSION - 5R55E - GEAR WHINE NOISE IN 1ST AND 2ND GEAR ONLY - VEHICLES EQUIPPED WITH 4.0L ENGINE ONLY FORD: 2001-2003 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER ISSUE Some 2001-2003 Rangers, 2001-2003 Explorer Sport/Sport Trac, built prior to 10/18/2002, equipped with a 5R55E automatic transmission and 4.0L engine, may exhibit a gear whine type of noise in 1st and 2nd gear ONLY. This may be caused by the Reverse and Forward Planetary assemblies and/or the driveshaft. ACTION Verify that only these conditions exist and no DTCs are present. If other conditions are present and DTCs exist they must be diagnosed and serviced first. Once all other conditions are serviced and only the 1st and 2nd gear whine are still present, refer to the following Service Procedure. Using the chart provided, select the parts that need to be replaced. NOTE IF PLANETARIES ARE LISTED, BOTH MUST BE REPLACED. SERVICE PROCEDURE Gear Whine Service Procedure 1. Determine whether the driveshaft only, planetaries only or both driveshaft and planetaries need to be replaced, refer to Application and Component replacement chart shown. 2. If just the driveshaft needs to be replaced follow the procedures as listed in the appropriate Workshop Manual section for driveshaft removal/replacement. 3. If the planetaries need to be replaced, using the appropriate model and year Workshop Manual, Section 307-01, Transmission Removal procedures, remove the transmission. 4. Discard the driveshaft ONLY if being replaced. Refer to application and component replacement chart. NOTE REPLACEMENT OF THE EXTENSION HOUSING SEAL AND BUSHING ARE NOT REQUIRED. DO NOT DISASSEMBLE BEYOND THE REVERSE PLANETARY. ALL SUBASSEMBLY STEPS ARE NOT REQUIRED FOR THIS PROCEDURE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Planetary Gears: > 02-22-2 > Nov > 02 > A/T - 5R55E 1st/2nd Gear Whining Noise > Page 5347 NOTE BOTH PLANETARIES MUST BE REPLACED OR THE REPAIR MAY NOT BE EFFECTIVE. 5. Using the Transmission Disassembly procedures remove the Forward Planetary Assembly (7A398) and the Reverse Planetary Assembly (7D006) and discard. Do not disassemble beyond the Reverse Planetary assembly. 6. Using the appropriate Transmission Assembly procedures, assemble the transmission and install BOTH NEW service Reverse Planetary Assembly (XL2Z-7D006-AA) and a new service Forward Planetary Assembly (XL2Z-7A398-AA). 7. Using the appropriate model and year Workshop Manual, Section 307-01, Transmission Installation procedures, install transmission. 8. If being replaced, Install the NEW service driveshaft 2L2Z-4602-AA as required for the appropriate application listed. 9. Verify repair. Clear DTCs. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 022202A Replace Transmission 5.5 Hrs. Forward And Reverse Planetary Assemblies (Includes Time To Remove And Install Transmission 5R55E) 2001-2003 Explorer Sport/Sport Trac And Ranger 4.0L 4X2 022202B Replace Transmission 7.0 Hrs. Forward And Reverse Planetary Assemblies (Includes Time To Remove And Install Transmission 5R55E) 2001-2003 Explorer Sport/Sport Trac And Ranger 4.0L 4X4 022202C Replace Driveshaft 0.4 Hr. Only 2002-2003 Explorer Sport Trac 4x2 DEALER CODING CONDITION BASIC PART NO. CODE 7A398 42 OASIS CODES: 501000 502000, 504000, 597997, 703200, 703400 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Planetary Gears: > 02-22-2 > Nov > 02 > A/T - 5R55E 1st/2nd Gear Whining Noise > Page 5348 DISCLAIMER Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations Pressure Regulating Solenoid: Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 5352 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 5353 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 5354 SSA, SSC solenoids 1. TCC solenoid 2. SSB, SSD solenoids 3. EPC solenoid Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Pressure Regulating Solenoid: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. NOTE: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5357 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number or the component name in one of the the A-Z Component Lists, the Component Location description for that component can easily be found. See: Locations/Component Locations/A-Z Component List Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5358 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5359 the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5360 that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5361 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5362 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5363 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5364 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5365 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5366 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5367 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5368 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5369 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5370 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5371 Systems Overview Wire Color Code Identification Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5372 OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5373 Pressure Regulating Solenoid: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5374 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5375 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5376 Pressure Regulating Solenoid: Exploded Views Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5377 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5378 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5379 Pressure Regulating Solenoid: Electrical Diagrams Diagram 29-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5380 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5381 Pressure Regulating Solenoid: Description and Operation Electronic Pressure Control (EPC) Solenoid The electronic pressure control (EPC) solenoid is a variable force style (VFS) solenoid. The VFS type solenoid is an electro-hydraulic actuator combining a solenoid and a regulating valve. The powertrain control module (PCM) varies the current to the EPC solenoid. This action causes the solenoid to regulate transmission line pressure and line modulator pressure. This is done by producing resisting forces to the main regulator and line modulator circuits. These two circuits control clutch application pressures. The PCM has an adaptive learn strategy to electronically control the transmission which will automatically adjust the shift feel. When the battery has been disconnected or a new battery installed, certain transmission operating parameters may be lost. The PCM must relearn these parameters. During this learning process you may experience slightly firm shifts, delayed, or early shifts. This operation is considered normal and will not affect the function of the transmission. Normal operation will return once these parameters are stored by the PCM. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5382 Pressure Regulating Solenoid: Service and Repair Solenoids-Shift, Torque Converter Clutch, Electronic Pressure Control Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal If equipped, loosen the nut and position the heat shield out of the way. 4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid. 6. Remove the transmission fluid filter. 1 Remove the transmission fluid filter screw. 2 Remove the transmission fluid filter. 7. NOTE: Main control assembly does not need to be removed for solenoid service. Remove wire loom guide and protector. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5383 8. Disconnect the appropriate solenoid electrical connector. 1 Disconnect shift solenoids electrical connectors. 2 Disconnect the Torque Converter Clutch (TCC) solenoid electrical connector. 3 Disconnect the Electronic Pressure Control (EPC) solenoid electrical connector. 9. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve. CAUTION: Shift Solenoid (SSC) may pop out of its bore. This may damage the solenoid. Remove the shift solenoids. 1 Remove the wire harness 2 Remove the solenoid clamp screws. 3 Remove the solenoid clamp 4 Remove the appropriate solenoid(s) Installation 1. Install the new solenoid(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5384 2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 2W plug. Install the solenoid clamp 1 Position the solenoid clamp on the main control valve body. 2 Install the solenoid clamp screws. 3. Connect the six solenoid electrical connectors. 1 Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2 Connect the Torque Converter Clutch (TCC) solenoid electrical connector. 3 Connect the Electrical Pressure Control (EPC) solenoid electrical connector. 4. CAUTION: Excessive pressure may break the retaining pins. Install the main control valve body wire loom. Align the retaining pins to the holes in the solenoid clamps and gently press in the main control valve body wire loom guide and protector. 5. Install the transmission fluid filter. 1 Install the transmission fluid filter. 2 Install the transmission fluid filter screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5385 6. Install the transmission fluid pan. 1 Position a new transmission fluid pan gasket on the transmission fluid pan. 2 Align and install the transmission fluid pan. - Loosely install the transmission fluid pan screws. 7. Tighten the transmission fluid pan screws. - Tighten the transmission fluid pan screws in a crisscross sequence. 8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle. 10. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. 11. Fill the transmission to the correct fluid level and check for correct transmission operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal and Bushing Seals and Gaskets: Service and Repair Extension Housing Seal and Bushing Extension Housing Seal and Bushing Special Tools Special Tool(s) Removal 1. Position the vehicle on a hoist. Place in NEUTRAL. 2. NOTE: To maintain initial driveshaft balance mark the rear driveshaft yoke and axle flange so they can be installed in their original alignment. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal and Bushing > Page 5390 Mark the rear driveshaft. 3. Remove the rear driveshaft. 1 Remove the rear driveshaft bolts. 2 Remove the rear driveshaft. 4. Using the special tools, remove the extension housing seal. 5. CAUTION: Use the extension housing bushing remover carefully so that the seal area is not damaged. Using the special tool, remove the extension housing bushing. Installation 1. CAUTION: The lube hole in the extension housing bushing must be aligned with the lube groove in the extension housing. This groove is located at the 3 o'clock position when viewed from the rear. NOTE: Inspect the counterbore of the extension housing for burrs. Remove any burrs from the extension housing counterbore with an oil stone. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal and Bushing > Page 5391 Position the extension housing bushing into the extension housing. 2. CAUTION: The tool will bottom when bushing is in the correct position. Using the special tool, install the extension housing bushing. 3. Position new extension housing seal with drain hole in the 6 o'clock position. 4. Using the special tool, install the extension housing seal. 5. NOTE: Inspect the driveshaft slip-yoke for wear and damage. Install a new component if required. Align the driveshaft with the marks made during removal to make sure balance is correct. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal and Bushing > Page 5392 6. NOTE: Align the driveshaft with the marks made during removal to make sure balance is correct. Install the rear driveshaft bolts. 7. Lower the vehicle. 8. Fill the transmission to the correct fluid level with clean automatic transmission fluid and check for correct transmission operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal and Bushing > Page 5393 Seals and Gaskets: Service and Repair Extension Housing Gasket Extension Housing Gasket Removal 1. Raise and support the vehicle. 2. NOTE: To maintain initial driveshaft balance, mark the rear driveshaft yoke and axle flange so they may be installed in their original alignment. Mark the rear driveshaft. 3. Remove the rear driveshaft. 1 Remove the bolts. 2 Remove the rear driveshaft. 4. Remove the nuts. 5. Raise and support the transmission. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal and Bushing > Page 5394 6. Remove the transmission mount. 1 Remove the screws. 2 Remove the transmission mount. 7. Remove the extension housing screws and studs. 8. CAUTION: The parking pawl, parking pawl return spring and parking pawl shaft could fall out during removal of the extension housing. Remove the extension housing. Discard the extension housing gasket. Installation 1. Clean the extension housing and install new extension housing gasket. Make sure that the parking pawl, spring and shaft are correctly installed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal and Bushing > Page 5395 2. CAUTION: Make sure the parking lever actuating rod is correctly seated into the case parking rod guide cup. Install the extension housing. 1 Position the extension housing. 2 Install the extension housing screws. 3 Install the extension housing studs. 3. Install the transmission mount. 1 Position the transmission mount on the extension housing. 2 Install the transmission mount-to-extension housing screws. 4. Install the transmission mount into the crossmember and tighten the transmission mount nuts. 5. NOTE: Align the driveshaft with the marks made during removal to ensure correct balance. Align and install the rear driveshaft. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal and Bushing > Page 5396 6. Install the bolts. 7. Lower the vehicle. 8. Fill the transmission to the correct fluid level and check for correct transmission operation. - Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON V specification. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams Connector View C167 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams Connector View C279 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > PCM Inputs Transmission Mode Switch: Description and Operation PCM Inputs TRANSMISSION CONTROL SWITCH Transmission Control Switch (TCS) Transmission Control Switch (TCS) The Transmission Control Switch (TCS) (Figures 43 and 44) signals the PCM with key power whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > PCM Inputs > Page 5406 Transmission Mode Switch: Description and Operation PCM Output Transmission Control Indicator Lamp The Transmission Control Indicator Lamp (TCIL) is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Refer to Transmission Control Switch in Hardware PCM Inputs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > Page 5407 Transmission Mode Switch: Service and Repair Transmission Control Switch Removal and Installation 1. Remove the Transmission Control Switch (TCS). 1 Remove the cover. 2 Remove the TCS. 2. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission Range (TR) sensor screws .......................................................................................................................... 8-11 Nm (71-97 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5411 View 151-5 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5412 Connector View C167 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5413 Digital Transmission Range Sensor: Description and Operation Digital Transmission Range (TR) Sensor The digital Transmission Range (TR) sensor is located on the outside of the transmission at the manual lever. The digital TR sensor completes the start circuit in PARK, NEUTRAL, and the back-up lamp circuit in REVERSE. The digital TR sensor also opens and closes a set of four switches that are monitored by the Powertrain Control Module (PCM) to determine the position of the manual lever (P, R, N, (D), 3, 2, 1). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5414 Digital Transmission Range Sensor: Service and Repair Digital Transmission Range (TR) Sensor Special Tools Special Tool(s) Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Disconnect the shift cable from the manual control lever. 4. Disconnect the digital Transmission Range (TR) sensor electrical connector. 5. Remove the manual control outer lever nut and manual control outer lever. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5415 6. Remove the screws and the digital TR sensor. Installation 1. Install the digital TR sensor and loosely install the screws. 2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence. 3. Install the manual control outer lever and nut. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5416 4. Connect the digital Transmission Range (TR) sensor electrical connector. 5. Connect the shift cable to the manual control lever. 6. Verify that the shift cable is adjusted. 7. Lower the vehicle. 8. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Turbine shaft speed (TSS) sensor screw ....................................................................................................................................... 8-11 Nm (71-97 inch lbs.) Output shaft speed sensor (OSS) sensor screw ............................................................................................................................. 8-11 Nm (71-97 inch lbs.) Intermediate shaft speed sensor (ISS) sensor ................................................................................................................................ 8-11 Nm (71-97 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor View 151-5 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 5422 Transmission Speed Sensor: Locations Output Shaft Speed Sensor View 151-5 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 5423 View 151-6 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Intermediate Shaft Speed Sensor Connector View C164 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Intermediate Shaft Speed Sensor > Page 5426 Transmission Speed Sensor: Diagrams Output Shaft Speed Sensor Connector View C193 Connector View C1107 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5427 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED SENSOR The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Removal 1. Raise and support the vehicle. 2. Disconnect Output Shaft Speed (OSS) sensor electrical connector. 3. Remove OSS sensor. 1 Remove the OSS sensor screw. 2 Remove the OSS sensor from the transmission. - Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring. Installation 1. Inspect and lubricate O-ring with petroleum jelly. 1 Install the OSS sensor into the transmission. 2 Tighten OSS sensor screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor > Page 5430 2. Connect OSS sensor electrical connector. 3. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor > Page 5431 Transmission Speed Sensor: Service and Repair Intermediate Shaft Speed Sensor Intermediate Shaft Speed Sensor Removal 1. Raise and support the vehicle. 2. Disconnect Intermediate Shaft Speed (ISS) sensor electrical connector. 3. Remove ISS sensor. 1 Remove the ISS sensor screw. 2 Remove the ISS sensor from the transmission. - Inspect the ISS sensor O-ring for damage. If damaged, install a new O-ring. Installation 1. Inspect and lubricate O-ring with petroleum jelly. 1 Install the ISS sensor into the transmission. 2 Tighten ISS sensor screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor > Page 5432 2. Connect ISS sensor electrical connector. 3. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations The Transmission Fluid Temperature Sensor is located on the solenoid body. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Temperature Sensor/Switch: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. NOTE: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5438 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number or the component name in one of the the A-Z Component Lists, the Component Location description for that component can easily be found. See: Locations/Component Locations/A-Z Component List Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5439 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5440 the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5441 that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5442 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5443 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5444 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5445 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5446 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5447 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5448 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5449 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5450 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5451 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5452 Systems Overview Wire Color Code Identification Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5453 OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5454 Transmission Temperature Sensor/Switch: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5455 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5456 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5457 Transmission Temperature Sensor/Switch: Electrical Diagrams Diagram 29-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5458 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Page 5459 Transmission Temperature Sensor/Switch: Description and Operation Transmission Fluid Temperature (TFT) Sensor The transmission fluid temperature (TFT) sensor is a thermistor-type sensor that varies a reference voltage signal. The resistance in the TFT varies with temperature. The powertrain control module (PCM) monitors the voltage signal across the TFT, and uses this information to determine the transmission fluid temperature. The TFT is located on the main control body wiring harness assembly. The PCM uses the TFT signal to help determine shift scheduling, torque converter clutch operation and electronic pressure control (EPC). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Specifications Shift Interlock Solenoid: Specifications Bolts retaining the shift lock actuator to the transmission column shift selector tube ............................................................................. 9 Nm (80 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 5464 Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator Removal and Installation 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches.Please refer to the appropriate location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable. Wait at least one minute before proceeding with the procedure to allow the backup power supply to deplete its energy. 2. Remove the lower steering column opening finish panel. 1 Remove the screws and position the hood release handle out of the way. 2 Remove the two screws from the lower steering column opening finish panel. 3 Pull outward to release the retaining clips and remove the lower steering column opening finish panel. 3. Remove the five bolts and the lower steering column opening finish panel reinforcement. 4. Remove the four nuts and lower the steering column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 5465 5. Remove the three bolts and separate the insert plate and shift lock actuator from the steering column. 6. Disconnect the electrical connector and remove the insert plate and shift lock actuator. 7. NOTE: The shift lock actuator clip is an assembly aid for the assembly plant. It is not necessary to install a new clip for installation. Remove and discard the clip. 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications Shift Solenoid: Specifications Solenoid clamp screws ........................................................................................................................ ............................................ 6-8 Nm (53-71 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications > Page 5469 Shift Solenoid: Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications > Page 5470 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications > Page 5471 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications > Page 5472 SSA, SSC solenoids 1. TCC solenoid 2. SSB, SSD solenoids 3. EPC solenoid Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. NOTE: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5475 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number or the component name in one of the the A-Z Component Lists, the Component Location description for that component can easily be found. See: Locations/Component Locations/A-Z Component List Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5476 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5477 the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5478 that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5479 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5480 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5481 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5482 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5483 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5484 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5485 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5486 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5487 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5488 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5489 Systems Overview Wire Color Code Identification Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5490 OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5491 Shift Solenoid: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5492 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5493 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5494 Shift Solenoid: Exploded Views Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5495 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5496 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5497 Shift Solenoid: Electrical Diagrams Diagram 29-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5498 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 5499 Shift Solenoid: Description and Operation Shift Solenoids A, B, C, and D Four On/Off shift solenoids allow the powertrain control module to control shift scheduling. - The solenoids are two-way, normally open style. - The shift solenoids (SSA, SSB, SSC, and SSD) provide gear selection by controlling the pressures of the shift valves. - SSD is also used to apply and release the coast clutch. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 5500 Shift Solenoid: Service and Repair Solenoids-Shift, Torque Converter Clutch, Electronic Pressure Control Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal If equipped, loosen the nut and position the heat shield out of the way. 4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid. 6. Remove the transmission fluid filter. 1 Remove the transmission fluid filter screw. 2 Remove the transmission fluid filter. 7. NOTE: Main control assembly does not need to be removed for solenoid service. Remove wire loom guide and protector. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 5501 8. Disconnect the appropriate solenoid electrical connector. 1 Disconnect shift solenoids electrical connectors. 2 Disconnect the Torque Converter Clutch (TCC) solenoid electrical connector. 3 Disconnect the Electronic Pressure Control (EPC) solenoid electrical connector. 9. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve. CAUTION: Shift Solenoid (SSC) may pop out of its bore. This may damage the solenoid. Remove the shift solenoids. 1 Remove the wire harness 2 Remove the solenoid clamp screws. 3 Remove the solenoid clamp 4 Remove the appropriate solenoid(s) Installation 1. Install the new solenoid(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 5502 2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 2W plug. Install the solenoid clamp 1 Position the solenoid clamp on the main control valve body. 2 Install the solenoid clamp screws. 3. Connect the six solenoid electrical connectors. 1 Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2 Connect the Torque Converter Clutch (TCC) solenoid electrical connector. 3 Connect the Electrical Pressure Control (EPC) solenoid electrical connector. 4. CAUTION: Excessive pressure may break the retaining pins. Install the main control valve body wire loom. Align the retaining pins to the holes in the solenoid clamps and gently press in the main control valve body wire loom guide and protector. 5. Install the transmission fluid filter. 1 Install the transmission fluid filter. 2 Install the transmission fluid filter screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 5503 6. Install the transmission fluid pan. 1 Position a new transmission fluid pan gasket on the transmission fluid pan. 2 Align and install the transmission fluid pan. - Loosely install the transmission fluid pan screws. 7. Tighten the transmission fluid pan screws. - Tighten the transmission fluid pan screws in a crisscross sequence. 8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle. 10. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. 11. Fill the transmission to the correct fluid level and check for correct transmission operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Adjustments Shifter A/T: Adjustments Selector Lever Indicator Adjustment 1. Remove the lower steering column opening finish panel. 1 Remove the screws and position the hood release handle out of the way. 2 Remove the two screws from the lower steering column opening finish panel. 3 Pull outward to release the retaining clips and remove the lower steering column opening finish panel. 2. Remove the five bolts and the lower steering column opening finish panel reinforcement. 3. Rotate the gearshift lever clockwise until it bottoms out (first gear), then rotate it counterclockwise two detents ((D) position). 4. Hang a 1.4 kg (3 lb) weight on the gearshift lever. 5. Rotate the thumb wheel to center the selector lever indicator in the middle of the (D) position. 6. Remove the 1.4 kg (3 lb) weight. 7. Rotate the gearshift lever into each detent to verify that the selector lever indicator matches the selected range. Readjust, if necessary. 8. Install the lower steering column opening finish panel reinforcement. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Adjustments > Page 5507 9. Install the lower steering column opening finish panel and the hood release handle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Adjustments > Page 5508 Shifter A/T: Service and Repair Selector Lever Removal and Installation 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please refer to the appropriate location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable. Wait at least one minute before proceeding with the procedure to allow the backup power supply to deplete its energy. 2. Remove the lower steering column opening finish panel. 1 Remove the screws and position the hood release handle out of the way. 2 Remove the two screws from the lower steering column opening finish panel. 3 Pull outward to release the retaining clips and remove the lower steering column opening finish panel. 3. Remove the five bolts and the lower steering column opening finish panel reinforcement. 4. Remove the four nuts and lower the steering column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Adjustments > Page 5509 5. Remove the ignition switch lock cylinder. 1 Rotate the ignition switch lock cylinder to the RUN position. 2 Press the lock cylinder release pin and remove the ignition switch lock cylinder. 6. Remove the lower steering column shroud. 1 If so equipped, remove the tilt wheel handle and shank. 2 Remove the three screws. 3 Remove the lower steering column shroud. 7. Remove the upper steering column shroud. 8. Disconnect the Transmission Control Switch (TCS) harness connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Adjustments > Page 5510 9. Separate the TCS harness from the locators and the gearshift lever cover from the steering column. 10. CAUTION: Never reinstall the old gearshift lever pin. Remove the gearshift lever pin and the gearshift lever. Discard the gearshift lever pin. 11. To install, reverse the removal procedure. 12. Prove out the air bag system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Service and Repair Selector Shaft: Service and Repair Manual Control Lever Shaft and Seal Special Tools Special Tool(s) Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support vehicle. 3. NOTE: If equipped, transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. If equipped, loosen the nut and position the heat shield out of the way. 4. NOTE: It is not necessary to remove the transmission fluid filter to carry out this procedure. Remove the transmission fluid pan. 5. Remove the digital Transmission Range (TR) sensor. 6. Remove the manual control valve detent lever spring. 1 Remove the manual control valve detent lever spring screw. 2 Remove the manual control valve detent lever spring. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Service and Repair > Page 5515 7. CAUTION: Do not damage the valve inner lever pin. Remove the manual valve inner lever nut. 8. Separate the manual valve inner lever and the parking lever actuating rod. 9. CAUTION: Do not damage the case fluid pan rail. Remove the manual control lever shaft spring pin. Tap lightly on each side of the manual control lever shaft spring pin with a drift punch. - Pry the spring pin out of its bore. 10. Remove the manual control lever shaft. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Service and Repair > Page 5516 11. CAUTION: Do not damage the bore. Remove the manual control lever shaft seal. Installation 1. Using the special tool, install the manual control lever shaft seal. - Lubricate the manual control lever shaft seal with petroleum jelly. 2. Install the manual control lever shaft. 3. CAUTION: Use care not to damage the fluid pan rail surface when installing the retaining pin. Align the manual control lever shaft alignment groove with the manual control lever shaft spring pin bore in the transmission case. Tap the manual control lever shaft spring pin into the transmission case. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Service and Repair > Page 5517 4. Align flats of the manual valve inner lever with flats on the manual control lever shaft. Install the manual valve inner lever and parking lever actuating rod onto the manual control lever shaft. 5. CAUTION: Do not bend the manual valve inner lever pin. Install the manual valve inner lever nut. 6. CAUTION: Park pawl actuating rod must be correctly installed into parking pawl and guide cup located in extension housing. Verify park linkage function. Verify that the output shaft is locked in the PARK position. 7. Rotate the manual lever into the NEUTRAL position and install the manual valve detent spring. 8. Install the transmission fluid pan with new pan gasket. 9. If equipped, position the servo heat shield over the servos and clip it to the pan rail. 10. Install the digital Transmission Range (TR) sensor. 11. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Service and Repair > Page 5518 12. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. 13. Fill the transmission to correct level and check for correct transmission operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications Shift Cable: Specifications Bolts retaining the shift cable bracket to the transmission ........................................................................................................................ 40 Nm (30 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > Page 5522 Shift Cable: Adjustments Selector Lever Cable Adjustment 1. Rotate the gearshift lever clockwise until it bottoms out (first gear), then rotate it counterclockwise two detents ((D) position). 2. Hang a 1.4 kg (3 lb) weight on the gearshift lever. 3. Raise and support the vehicle. 4. CAUTION: Adjust the shift cable only in the (D) position. Adjust the shift cable. 1 Disconnect the shift cable from the manual control lever. 2 Insert a flat blade screwdriver between the end of the shift cable adjustment lock tab and the housing and twist the screwdriver to disengage the lock tab snaps. Pull the shift cable adjustment lock tab outward to the unlock position. 3 Place the manual control lever in the (D) position. - Rotate the manual control lever forward until travel stops. Then, move the manual control lever back two detents to the (D) position. 4 Connect the shift cable to the manual control lever. 5 Push the shift cable adjustment lock tab inward to the lock position. 5. Lower the vehicle. 6. Remove the 1.4 kg (3 lb) weight. 7. Verify that the engine will start in P and N and that the reversing lamps illuminate in R. If not, repeat the adjustment procedure. 8. Check that the Digital Transmission Range (DTR) sensor adjustment is correct. Adjust the DTR sensor if necessary. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > Page 5523 Shift Cable: Service and Repair Selector Lever Cable and Bracket Removal 1. Raise and support the vehicle. 2. Disconnect the shift cable from the transmission. 1 Disconnect the shift cable from the manual control lever. 2 Depress the lock tabs and disconnect the shift cable from the shift cable bracket. 3. Remove the bolts and the shift cable bracket from the transmission. 4. Lower the vehicle. 5. Disconnect the shift cable from the steering column. 1 Disconnect the shift cable from the transmission selector lever arm and support. 2 Disconnect the shift cable from the steering column bracket. 6. Push the rubber grommet through the bulkhead. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > Page 5524 7. Locate the shift cable retainer tabs, protruding through the floor pan, underneath the carpet and insulation. While squeezing the tabs together, push the tabs out of the floor pan. 8. From the engine compartment, remove the shift cable from the vehicle. Installation 1. From inside the vehicle, feed the shift cable through the opening in the bulkhead and downward toward the transmission. Do not seat the rubber grommet in the bulkhead opening at this time. 2. Connect the shift cable to the steering column. 1 Connect the shift cable to the steering column bracket. 2 Connect the shift cable to the transmission selector lever arm and support. 3. From the engine compartment, connect the shift cable retainer to the floor pan. 4. From inside the vehicle, verify that the retainer tabs have seated on the floor pan. Reposition the insulation and the carpet. 5. Seat the rubber grommet in the bulkhead opening. 6. Rotate the gearshift lever clockwise until it bottoms out (first gear), then rotate it counterclockwise two detents ((D) position). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > Page 5525 7. Hang a 1.4 kg (3 lb) weight on the gearshift lever. 8. Raise and support the vehicle. 9. Position the shift cable bracket and install the bolts. 10. Connect the shift cable to the shift cable bracket. Do not connect the shift cable to the manual control lever at this time. 11. Adjust the shift cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams Connector View C167 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications Torque Converter: Specifications Torque converter-to-flexplate nuts ................................................................................................................................................. 30-40 Nm (22-30 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations Torque Converter Clutch Solenoid: Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 5535 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 5536 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 5537 SSA, SSC solenoids 1. TCC solenoid 2. SSB, SSD solenoids 3. EPC solenoid Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. NOTE: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5540 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number or the component name in one of the the A-Z Component Lists, the Component Location description for that component can easily be found. See: Locations/Component Locations/A-Z Component List Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5541 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5542 the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5543 that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5544 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5545 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5546 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5547 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5548 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5549 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5550 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5551 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5552 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5553 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5554 Systems Overview Wire Color Code Identification Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5555 OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5556 Torque Converter Clutch Solenoid: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5557 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5558 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5559 Torque Converter Clutch Solenoid: Exploded Views Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5560 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5561 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5562 Torque Converter Clutch Solenoid: Electrical Diagrams Diagram 29-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5563 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5564 Torque Converter Clutch Solenoid: Description and Operation Torque Converter Clutch (TCC) Solenoid The torque converter clutch (TCC) solenoid is used to control the apply and release of the TCC. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5565 Torque Converter Clutch Solenoid: Service and Repair Solenoids-Shift, Torque Converter Clutch, Electronic Pressure Control Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal If equipped, loosen the nut and position the heat shield out of the way. 4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid. 6. Remove the transmission fluid filter. 1 Remove the transmission fluid filter screw. 2 Remove the transmission fluid filter. 7. NOTE: Main control assembly does not need to be removed for solenoid service. Remove wire loom guide and protector. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5566 8. Disconnect the appropriate solenoid electrical connector. 1 Disconnect shift solenoids electrical connectors. 2 Disconnect the Torque Converter Clutch (TCC) solenoid electrical connector. 3 Disconnect the Electronic Pressure Control (EPC) solenoid electrical connector. 9. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve. CAUTION: Shift Solenoid (SSC) may pop out of its bore. This may damage the solenoid. Remove the shift solenoids. 1 Remove the wire harness 2 Remove the solenoid clamp screws. 3 Remove the solenoid clamp 4 Remove the appropriate solenoid(s) Installation 1. Install the new solenoid(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5567 2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 2W plug. Install the solenoid clamp 1 Position the solenoid clamp on the main control valve body. 2 Install the solenoid clamp screws. 3. Connect the six solenoid electrical connectors. 1 Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2 Connect the Torque Converter Clutch (TCC) solenoid electrical connector. 3 Connect the Electrical Pressure Control (EPC) solenoid electrical connector. 4. CAUTION: Excessive pressure may break the retaining pins. Install the main control valve body wire loom. Align the retaining pins to the holes in the solenoid clamps and gently press in the main control valve body wire loom guide and protector. 5. Install the transmission fluid filter. 1 Install the transmission fluid filter. 2 Install the transmission fluid filter screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5568 6. Install the transmission fluid pan. 1 Position a new transmission fluid pan gasket on the transmission fluid pan. 2 Align and install the transmission fluid pan. - Loosely install the transmission fluid pan screws. 7. Tighten the transmission fluid pan screws. - Tighten the transmission fluid pan screws in a crisscross sequence. 8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle. 10. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. 11. Fill the transmission to the correct fluid level and check for correct transmission operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Cooler Flushing Service Tips Transmission Cooler: Technical Service Bulletins A/T - Cooler Flushing Service Tips Article No. 03-14-8 07/21/03 TRANSMISSION - NEW TRANSMISSION COOLER FLUSHER - SERVICE TIPS FORD: 1992-1997 CROWN VICTORIA, PROBE, THUNDERBIRD 1992-2003 ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1992-1996 BRONCO 1992-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1992-1999 F-250 LD 1992-2003 ECONOLINE, EXPLORER, F-150, RANGER 1995-2003 WINDSTAR 1997-2003 EXPEDITION 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1992-1997 TOWN CAR 1992-2002 CONTINENTAL 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD 2003 AVIATOR MERCURY: 1992-1997 COUGAR, GRAND MARQUIS 1992-2000 TRACER 1992-2003 SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER This article supersedes TSB 00-1-5. ISSUE The number one cause for repeat transmission repairs is that contamination from the transmission cooler system (lines and tank) will work their way back into the rebuilt or new transmission. For this reason a new transmission cooler flusher has been released, "Turbo-Tank Heated Cooler Line Flusher" Rotunda Tool number 22-00001. ACTION The transmission cooling system (cooler and lines) MUST be flushed every time the transmission is overhauled or replaced in order to minimize the likelihood of repeat repairs. The use of this new "Turbo-Tank Heated Cooler Line Flusher" (222-00001) is the most effective way to remove contamination from its cooling system. Refer to the following Service Procedure and Equipment instructions (supplied with the "Turbo-Tank Heated Cooler Line Flusher"). SERVICE PROCEDURE Prior methods of cooler flushing have not obtained the level of cooler cleaning and contaminant removal that is required to prevent repeat repairs. The "Turbo-Tank Heated Cooler Line Flusher" uses heated Automatic Transmission Fluid (ATF) and a pulsating action to loosen system contamination. Previous equipment used solvents to clean & flush coolers, lines and torque-converters. There are 2 issues with this method: Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Cooler Flushing Service Tips > Page 5573 ^ Residual solvent contamination can cause damage to friction bonding materials within the transmission (Clutches and Bands). ^ Lack of fluid heating and agitation prevents this method from completely removing contamination from lines, in-radiator coolers and auxiliary coolers. Aerosol Solvents should never be used for several reasons. ^ They do not provide the volume necessary to remove heavy contaminants. ^ They evaporate quickly and essentially leave contaminants in pockets, bends, or wherever they are as the solvent dries. NOTE YOU MUST IDENTIFY THE RETURN COOLER LINE TO START THE BACK FLUSHING PROCEDURE. A quick way to identify the return cooler line (fluid coming out of the cooler and returning to the transmission) is to locate the return cooler line fitting on the transmission case. Refer to the following lists: Rear Wheel Drive ^ TORQSHIFT, 4R100, E40D, C6 - The REAR transmission case filling receives the return line. ^ 4R70W, AODE, AOD - The TOP transmission case filling receives the return line. ^ A4LD, 4R44/55E, 5R55E, 5R55N, 5R55W, 5R55S - The TOP transmission case filling receives the return line. Front Wheel Drive ^ CD4E - The REAR or Pump End transaxle case fitting receives the return line. ^ 4F27E - The REAR or Cover End transaxle case fitting receives the return line. ^ AXOD, AXODE, AX4S, AX4N, 4F50N - The BOTTOM transaxle cooler line fitting receives the return line. NOTE IF AN IN-LINE FILTER HAS BEEN INSTALLED IN THE COOLER LINE, IT MUST BE REMOVED BEFORE FLUSHING THE COOLER OR COOLER LINES. Purge the cooler and cooler line before flushing: Located on the "Turbo-Tank Heated Cooler Line Flusher" is a fluid transfer and purge valve. This valve can be used to purge the cooler and cooler lines of contaminated fluid before starting the back flush procedure of the fluid cooling system (refer to step 5a of this Service Procedure or Equipment instructions, supplied with the "Turbo-Tank Heated Cooler Line Flusher"). Flush Procedure 1. Check and top off fluid level of the "Turbo-Tank Heated Cooler Line Flusher" tank with transmission fluid. 2. Allow the fluid in the flusher 15-30 minutes to heat up to 140° F (60° C) before using. 3. Install line adapters into the transmission cooler lines. 4. Attach the flusher's blue line to the transmission return cooler line quick disconnect. 5. Attach the flusher's red line to the transmission outlet cooler line quick disconnect. a. Follow equipment instructions, to purge cooler lines and cooler prior to starting flushing procedure (using factory installed purge valve and clear hose on "Turbo-Tank Heated Cooler Line Flusher"). 6. Allow the cooling system to back-flush for 10-15 minutes, then flush the cooler in a forward/normal flow direction for an additional 10-15 minutes. For ordering information on this new "Turbo-Tank Heated Cooler Line Flusher" (222-00001), contact Rotunda at 800-ROTUNDA (800-768-8632 or outside U.S. 262-656-5805). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Cooler Flushing Service Tips > Page 5574 CAUTION THIS FLUSHER CANNOT BE USED TO FLUSH COOLERS ON VEHICLES EQUIPPED WITH THE TEMPERATURE BYPASS-TYPE TRANSMISSION COOLER CURRENTLY FOUND IN 1998-2003 CROWN VICTORIA, GRAND MARQUIS, AND TOWN CAR VEHICLES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-1-5 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Page 5575 Transmission Cooler: Specifications Transmission cooler lines to case connectors ................................................................................................................................. 35-43 Nm (26-32 ft. lbs.) Transmission cooler line nut .......................................................................................................................................................... 24-31 Nm (18-23 ft. lbs.) Transmission auxiliary fluid cooler bolts ........................................................................................................................................ 5-7 Nm (45-62 inch lbs.) Transmission auxiliary fluid cooler hose clamps ............................................................................................................................ 3-4 Nm (27-35 inch lbs.) Transmission fluid cooler tube fitting-to-radiator .......................................................................................................................... 13-22 Nm (10-16 ft. lbs.) Transmission cooler lines bracket bolts .................................................................................................................................... 3.1-4.3 Nm (28-38 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Page 5576 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Page 5577 Transmission Cooler: Description and Operation Transmission Cooling All vehicles with automatic transmissions are equipped with integral transmission fluid coolers. The integral transmission fluid cooler is contained inside of the radiator outlet tank and cannot be repaired separately. All (AWD) vehicles are equipped with the transmission auxiliary fluid cooler, which is mounted in front of the radiator. In operation, transmission fluid travels from the transmission to the integral transmission fluid cooler to the transmission auxiliary fluid cooler then back to the transmission. The integral transmission fluid cooler transfers heat from the transmission fluid to the engine coolant. The transmission auxiliary fluid cooler transfers heat from the transmission fluid to the outside air. Transmission Cooling Components (Mountaineer Shown, Explorer Similar) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Transmission Cooler: Initial Inspection and Diagnostic Overview Inspection and Verification WARNING: Never remove the radiator cap under any conditions while the engine is operating. Failure to follow these instructions could result in personal injury and/or damage to the cooling system or engine. To avoid having scalding hot coolant or steam blow out of the radiator, use extreme care when removing the radiator cap from a hot radiator. Wait until the engine has cooled, then wrap a thick cloth around the radiator cap and turn it slowly to the first stop. Step back while the pressure is released from the cooling system. When you are certain all the pressure has been released, press down on the radiator cap (with a cloth), turn and remove. Check for fluid leakage. If fluid leakage is found at any of the transmission fluid cooling components, the component must be replaced. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5580 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Auxiliary Transmission Fluid Cooler Transmission Cooler: Service and Repair Auxiliary Transmission Fluid Cooler Auxiliary Transmission Fluid Cooler Removal 1. Disconnect the battery cables. 2. Raise and support the vehicle. 3. Remove the radiator air deflector. 1 Remove the bolts. 2 Remove the radiator air deflector. 4. Place a drain pan under the transmission auxiliary fluid cooler. 5. Loosen the two upper radiator hold down screws. 6. Remove the transmission auxiliary fluid cooler. 1 Disconnect the hoses. 2 Remove the bolts. 3 Remove the transmission auxiliary fluid cooler. Installation Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Auxiliary Transmission Fluid Cooler > Page 5583 1. Follow the removal procedure in reverse order. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Auxiliary Transmission Fluid Cooler > Page 5584 Transmission Cooler: Service and Repair Transmission Fluid Cooler Tubes Transmission Fluid Cooler Tubes Removal 1. Raise and support the vehicle. 2. Remove the radiator air deflector. 1 Remove the bolts. 2 Remove the radiator air deflector. 3. Remove the nut, bolt and transmission cooler line bracket. 4. Remove the transmission fluid cooler tubes. 1 Remove the clips. 2 Disconnect the fittings. Use a backup wrench to hold the case fitting secure. 3 Remove the nut. 4 Remove the transmission fluid cooler tubes. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Auxiliary Transmission Fluid Cooler > Page 5585 Installation 1. NOTE: When a transmission fluid cooler tube is replaced, each replacement tube must be fabricated from the same size tube as the original. Shape a new transmission fluid cooler tube. Use the prior tube as a guide. - Install the appropriate fittings. 2. CAUTION: To prevent damage, make sure all plugs are removed from port openings before installing tubes. CAUTION: To prevent cross threading, all tube nuts must be hand started before being torqued to specification. Install the transmission fluid cooler tubes. 1 Install the clips. 2 Connect the tube fittings to the radiator. 3 Connect the tube fittings to the transmission. Use a backup wrench to hold the case fitting secure. 4 Install the tube bracket nut. 5 Install the transmission fluid cooler tubes. 3. Install the nut, bolt, and transmission cooler line bracket. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Auxiliary Transmission Fluid Cooler > Page 5586 4. Install the radiator air deflector. - Install the bolts. 5. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. 6. Fill transmission fluid to the proper level using the correct fluid and inspect for leaks. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams Connector View C279 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Description and Operation > PCM Inputs Transmission Mode Switch: Description and Operation PCM Inputs TRANSMISSION CONTROL SWITCH Transmission Control Switch (TCS) Transmission Control Switch (TCS) The Transmission Control Switch (TCS) (Figures 43 and 44) signals the PCM with key power whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Description and Operation > PCM Inputs > Page 5592 Transmission Mode Switch: Description and Operation PCM Output Transmission Control Indicator Lamp The Transmission Control Indicator Lamp (TCIL) is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Refer to Transmission Control Switch in Hardware PCM Inputs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Description and Operation > Page 5593 Transmission Mode Switch: Service and Repair Transmission Control Switch Removal and Installation 1. Remove the Transmission Control Switch (TCS). 1 Remove the cover. 2 Remove the TCS. 2. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Specifications Transmission Mount: Specifications Transmission mount nuts to crossmember ................................................................................................................................... 87-110 Nm (64-81 ft. lbs.) Transmission mount-to-extension housing screws ....................................................................................................................... 87-110 Nm (64-81 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Specifications > Page 5597 Transmission Mount: Service and Repair Transmission Insulator and Retainer Removal NOTE: 4x2 procedure shown. 4x4 similar, front drive shaft will need to be removed. 1. Raise and support the vehicle. 2. NOTE: To maintain initial driveshaft balance, mark the rear driveshaft yoke and axle flange so they may be installed in their original alignment. Mark the rear driveshaft. 3. Remove the rear driveshaft. 1 Remove the bolts. 2 Remove the rear driveshaft. 4. Remove the transmission mount nuts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Specifications > Page 5598 5. Raise and support the transmission. 6. Remove the transmission mount. 1 Remove the screws. 2 Remove the transmission mount. Installation 1. Install the transmission mount. 1 Position the transmission mount on the extension housing. 2 Install the transmission mount-to-extension housing screws. 2. Install the transmission mount into the crossmember and tighten the nuts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Specifications > Page 5599 3. NOTE: Align the driveshaft with the marks made during removal to ensure correct balance. Align and install the rear driveshaft. 4. Install the bolts. 5. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission Range (TR) sensor screws .......................................................................................................................... 8-11 Nm (71-97 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5603 View 151-5 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5604 Connector View C167 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5605 Digital Transmission Range Sensor: Description and Operation Digital Transmission Range (TR) Sensor The digital Transmission Range (TR) sensor is located on the outside of the transmission at the manual lever. The digital TR sensor completes the start circuit in PARK, NEUTRAL, and the back-up lamp circuit in REVERSE. The digital TR sensor also opens and closes a set of four switches that are monitored by the Powertrain Control Module (PCM) to determine the position of the manual lever (P, R, N, (D), 3, 2, 1). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5606 Digital Transmission Range Sensor: Service and Repair Digital Transmission Range (TR) Sensor Special Tools Special Tool(s) Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Disconnect the shift cable from the manual control lever. 4. Disconnect the digital Transmission Range (TR) sensor electrical connector. 5. Remove the manual control outer lever nut and manual control outer lever. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5607 6. Remove the screws and the digital TR sensor. Installation 1. Install the digital TR sensor and loosely install the screws. 2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence. 3. Install the manual control outer lever and nut. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5608 4. Connect the digital Transmission Range (TR) sensor electrical connector. 5. Connect the shift cable to the manual control lever. 6. Verify that the shift cable is adjusted. 7. Lower the vehicle. 8. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Turbine shaft speed (TSS) sensor screw ....................................................................................................................................... 8-11 Nm (71-97 inch lbs.) Output shaft speed sensor (OSS) sensor screw ............................................................................................................................. 8-11 Nm (71-97 inch lbs.) Intermediate shaft speed sensor (ISS) sensor ................................................................................................................................ 8-11 Nm (71-97 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor View 151-5 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 5614 Transmission Speed Sensor: Locations Output Shaft Speed Sensor View 151-5 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 5615 View 151-6 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Intermediate Shaft Speed Sensor Connector View C164 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Intermediate Shaft Speed Sensor > Page 5618 Transmission Speed Sensor: Diagrams Output Shaft Speed Sensor Connector View C193 Connector View C1107 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5619 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED SENSOR The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Removal 1. Raise and support the vehicle. 2. Disconnect Output Shaft Speed (OSS) sensor electrical connector. 3. Remove OSS sensor. 1 Remove the OSS sensor screw. 2 Remove the OSS sensor from the transmission. - Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring. Installation 1. Inspect and lubricate O-ring with petroleum jelly. 1 Install the OSS sensor into the transmission. 2 Tighten OSS sensor screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor > Page 5622 2. Connect OSS sensor electrical connector. 3. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor > Page 5623 Transmission Speed Sensor: Service and Repair Intermediate Shaft Speed Sensor Intermediate Shaft Speed Sensor Removal 1. Raise and support the vehicle. 2. Disconnect Intermediate Shaft Speed (ISS) sensor electrical connector. 3. Remove ISS sensor. 1 Remove the ISS sensor screw. 2 Remove the ISS sensor from the transmission. - Inspect the ISS sensor O-ring for damage. If damaged, install a new O-ring. Installation 1. Inspect and lubricate O-ring with petroleum jelly. 1 Install the ISS sensor into the transmission. 2 Tighten ISS sensor screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor > Page 5624 2. Connect ISS sensor electrical connector. 3. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations The Transmission Fluid Temperature Sensor is located on the solenoid body. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Temperature Sensor/Switch: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. NOTE: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5630 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number or the component name in one of the the A-Z Component Lists, the Component Location description for that component can easily be found. See: Locations/Component Locations/A-Z Component List Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5631 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5632 the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5633 that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5634 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5635 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5636 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5637 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5638 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5639 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5640 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5641 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5642 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5643 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5644 Systems Overview Wire Color Code Identification Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5645 OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5646 Transmission Temperature Sensor/Switch: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5647 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5648 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5649 Transmission Temperature Sensor/Switch: Electrical Diagrams Diagram 29-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5650 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Page 5651 Transmission Temperature Sensor/Switch: Description and Operation Transmission Fluid Temperature (TFT) Sensor The transmission fluid temperature (TFT) sensor is a thermistor-type sensor that varies a reference voltage signal. The resistance in the TFT varies with temperature. The powertrain control module (PCM) monitors the voltage signal across the TFT, and uses this information to determine the transmission fluid temperature. The TFT is located on the main control body wiring harness assembly. The PCM uses the TFT signal to help determine shift scheduling, torque converter clutch operation and electronic pressure control (EPC). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 03-22-10 > Nov > 03 > A/T - No 2nd, 3rd Gear/No Engine Braking/DTC's Set Valve Body: Customer Interest A/T - No 2nd, 3rd Gear/No Engine Braking/DTC's Set Article No. 03-22-10 11/10/03 TRANSMISSION - 4R44E - 4R55E - 5R44E - 5R55E - LOW LINE PRESSURE READING AT WIDE OPEN THROTTLE (WOT) - POSSIBLE DIAGNOSTIC TROUBLE CODES P0732, P0733, P1762 - VEHICLES BUILT BEFORE 12/1/2001 FORD: 1995-2001 EXPLORER 1995-2002 RANGER 1996-1997 AEROSTAR 2000-2002 EXPLORER SPORT 2001-2002 EXPLORER SPORT TRAC MERCURY: 1997-2001 MOUNTAINEER This article supersedes TSB's 03-11-9, 02-13-8 and 02-08-2 to update the model coverage. ISSUE Some vehicles built prior to 12/1/2001 may exhibit the following shift and engagement conditions: ^ No 2nd Gear ^ No 3rd Gear ^ No Engine Braking In Manual 1st. Out of specification pressures controlled by the transmission main control valve body separator plate may be the cause. ACTION Verify the condition, the main control valve body separator plate may need to be updated to the latest level. Refer to the following Service Procedure for details. SERVICE PROCEDURE Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 03-22-10 > Nov > 03 > A/T - No 2nd, 3rd Gear/No Engine Braking/DTC's Set > Page 5660 CAUTION A NEW SEPARATOR 7Z490 MUST BE USED WHEN INSTALLING THE SPECIAL SERVICE KIT 7M203 OR ADDITIONAL TRANSMISSION DAMAGE MAY OCCUR. REFER TO THE PARTS APPLICATION CHART IN THIS ARTICLE FOR CORRECT SEPARATOR PLATE PART LISTING. NOTE THIS ARTICLE DOES NOT APPLY TO ANY OTHER CONDITIONS OR COMPONENTS THAT MAY CAUSE SIMILAR SYMPTOMS AND IS ONLY WRITTEN TO COVER THESE SPECIFIC CONDITIONS. NOTE AN IN-LINE SERVICE FILTER IS NOT REQUIRED TO BE ADDED OR REPLACED FOR THIS TSB. 1. Verify that one or more of the following conditions exist. ^ Low Line Pressure While In Drive At WOT ^ No 2nd And/Or No 3rd Gear Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 03-22-10 > Nov > 03 > A/T - No 2nd, 3rd Gear/No Engine Braking/DTC's Set > Page 5661 ^ No Engine Braking In Manual 1st ^ DTC P0732, P0733 Or P1762 2. Install kit (3L5Z-7M203-JA) to update the main control valve body assembly, refer to the installation procedures found in the kit. 3. Reinstall the main control by continuing to follow the installation steps listed in the Workshop Manual, in-vehicle service, main control valve body. 4. After completing the procedure, verify the condition has been corrected. 5. Clear all DTCs. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-11-9, 02-13-8 02-08-2 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 032210A Replace Separator Plate 2.8 Hrs. And Update Main Control Valve Body (Includes Time To Remove And Install Main Control Valve Body And Diagnosis) DEALER CODING CONDITION BASIC PART NO. CODE D100 D8 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 01-22-3 > Nov > 01 > A/T Buzzing Noise When Torque Converter Engaged Valve Body: Customer Interest A/T - Buzzing Noise When Torque Converter Engaged Article No. 01-22-3 11/12/01 ^ NOISE - BUZZING NOISE FROM THE TRANSMISSION WHEN THE TORQUE CONVERTER IS ENGAGED - VEHICLES PRODUCED 11/15/2000 THROUGH 11/11/2001 EQUIPPED WITH 4.6L ENGINE AND 5R55W TRANSMISSION ONLY ^ TRANSMISSION - 5R55W - BUZZING NOISE FROM THE TRANSMISSION WHEN THE TORQUE CONVERTER IS ENGAGED - VEHICLES PRODUCED 11/15/2000 THROUGH 11/11/2001 EQUIPPED WITH 4.6L ENGINE ONLY FORD: 2002 EXPLORER MERCURY: 2002 MOUNTAINEER ISSUE Some vehicles built prior to 11/11/2001 equipped with 5R55W and 4.6L engine, may exhibit a buzzing noise when the torque converter is engaged and the transmission fluid temperature is between 38-66°C (100-150 °F). This may be caused by a high velocity of fluid flow in the Main Control. ACTION Verity that the condition exists using the procedure listed. If the conditions described are verified, the Main Control will need to be replaced. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE THIS ARTICLE DOES NOT APPLY TO ANY OTHER CONDITIONS OR COMPONENTS THAT MAY CAUSE SIMILAR SYMPTOMS. 1. To verity that the condition exists with the vehicle, first connect a tachometer to the engine if the vehicle is not already equipped. 2. Install an NGS or equivalent and monitor the Transmission Fluid Temperature (TFT). 3. Start the engine and drive the vehicle. 4. When the TFT reaches 38°C (100 °F), maintain a constant speed of about 80 km/h (50 mph) to engage the converter. Tap the brake pedal with the left foot. Engine RPM should increase when the brake pedal has been tapped, and decrease after about five seconds after the pedal is released. 5. Maintaining a constant vehicle speed, allow the torque converter to re-engage. 6. Listen for the Torque Converter Clutch buzzing noise. Is the noise present? ^ If yes, continue with the verification. ^ If no, follow normal diagnosis as listed in the Workshop Manual, the Main Control is not the problem. 7. Continue to bring the transmission to operating temperature above 66°C (150°F). This may be accomplished by driving the vehicle for 15 to 20 minutes. 8. After normal operating temperature is reached, maintain a constant speed of about 80 km/h (50 mph) to engage the converter. Tap the brake pedal with the left foot. Engine RPM should increase when the brake pedal has been tapped, and decrease after about five seconds after the pedal is released. 9. Maintaining a constant vehicle speed, allow the torque converter to re-engage. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 01-22-3 > Nov > 01 > A/T Buzzing Noise When Torque Converter Engaged > Page 5666 10. Listen for the Torque Converter Clutch buzzing noise. Has the noise disappeared? ^ If yes, continue. ^ If no, follow normal diagnosis as listed in the Workshop Manuals, the Main Control is not the problem. 11. If the condition exists, drain the transmission fluid from the pan. NOTE AN IN-LINE SERVICE FILTER IS NOT REQUIRED TO BE ADDED OR REPLACED FOR THIS ARTICLE. 12. Replace the Main Control 1L2Z-7A100-CA and Fluid Filter 1L2Z-7A098-AC. Follow the steps listed in the Workshop Manual, In-Vehicle Service, Main Control Valve Body, to remove and replace. 13. Verify the condition has been corrected. 14. Clear all DTCs. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 012203A Verify Conditions And 2.6 Hrs. Replace Transmission Main Control DEALER CODING CONDITION BASIC PART NO. CODE 7A100 42 OASIS CODES: 504000, 702000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 01-20-7 > Oct > 01 > A/T 5R55W Ticking Noise Valve Body: Customer Interest A/T - 5R55W Ticking Noise Article No. 01-20-7 10/15/01 ^ NOISE -"TICK" NOISE FROM TRANSMISSION FRONT OR INTERMEDIATE SERVO COVER AREA - VEHICLES EQUIPPED WITH 5R55W TRANSMISSION - VEHICLES PRODUCED PRIOR TO 9/6/2001 ^ TRANSMISSION - 5R55W -"TICK" NOISE FROM TRANSMISSION FRONT OR INTERMEDIATE SERVO COVER AREA - VEHICLES PRODUCED PRIOR TO 9/6/2001 FORD: 2002 EXPLORER MERCURY: 2002 MOUNTAINEER ISSUE Some vehicles produced before 9/6/2001 equipped with the 5R55W transmission, may exhibit a tick noise emanating from the Front or Intermediate Servo Cover. This tick noise is only present at Idle in Park or Neutral. ACTION Verify that the condition exists and the noise is emanating from the Front or Intermediate Servo. If so, the Separator Plate 7Z490 or the Main Control may need to be replaced. Follow the service procedures for the repair. SERVICE PROCEDURE This TSB does not apply to any other ticking noises from transmission and vehicle components or locations. NOTE DO NOT ADD THE IN-LINE SERVICE FILTER AS LISTED IN THE WORKSHOP MANUAL. THE IN-LINE FILTER IS NOT REQUIRED TO BE ADDED FOR THIS TSB. 1. Verify that the condition exists ONLY during the following conditions: - at Idle, - while in Park and Neutral, - with the noise emanating from the Front or Intermediate Servos. 2. If the condition exists, drain the transmission fluid from the pan. 3. Remove the fluid pan and fluid pan gasket (the gasket is reusable). 4. Inspect the fluid in pan for major contamination. If major contamination is present, the Main Control (7A100) and Fluid Filter will need to be replaced. 5. If major contamination is not present, only the Main Control Separating Plate and fluid filter need to be replaced. 6. To replace ONLY the Main Control (7A100) and Fluid Filter (7A098), follow the steps listed in the Workshop Manual In-Vehicle Service, Main Control Valve Body, to remove and replace. 7. To replace ONLY the Main Control Separating Plate (7Z490) and Fluid Filter (7A098), follow the removal steps listed in the Workshop Manual In-Vehicle Service, Main Control Valve Body. 8. Once the Main Control Valve Body has been removed, rotate the body so that the separator is up and place on a clean work surface. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 01-20-7 > Oct > 01 > A/T 5R55W Ticking Noise > Page 5671 9. Remove the three screws that attach the plate to the main control, remove and discard the plate (Figure 1). 10. Make sure that the check balls are in there proper location (Figure 2). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 01-20-7 > Oct > 01 > A/T 5R55W Ticking Noise > Page 5672 11. lnstall the Special Service Tools 307-334 (2 required) on to the main control (Figure 3). 12. Install a NEW service Separator Plate, install the three (3) screws and tighten to 10 Nm (89 lb-in). Remove the Special Service Tools. 13. Reinstall the Main Control by continuing to follow the Installation steps listed in the Workshop Manual In-Vehicle Service, Main Control Valve Body. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 012007A Replace Main Control 1.8 Hrs. Valve Body And Fluid Filter 012007B Replace Main Control 1.9 Hrs. Valve Body Separator Plate And Fluid Filter DEALER CODING CONDITION BASIC PART NO. CODE 7Z490 42 OASIS CODES: 504000, 597997, 702000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 03-22-10 > Nov > 03 > A/T - No 2nd, 3rd Gear/No Engine Braking/DTC's Set Valve Body: All Technical Service Bulletins A/T - No 2nd, 3rd Gear/No Engine Braking/DTC's Set Article No. 03-22-10 11/10/03 TRANSMISSION - 4R44E - 4R55E - 5R44E - 5R55E - LOW LINE PRESSURE READING AT WIDE OPEN THROTTLE (WOT) - POSSIBLE DIAGNOSTIC TROUBLE CODES P0732, P0733, P1762 - VEHICLES BUILT BEFORE 12/1/2001 FORD: 1995-2001 EXPLORER 1995-2002 RANGER 1996-1997 AEROSTAR 2000-2002 EXPLORER SPORT 2001-2002 EXPLORER SPORT TRAC MERCURY: 1997-2001 MOUNTAINEER This article supersedes TSB's 03-11-9, 02-13-8 and 02-08-2 to update the model coverage. ISSUE Some vehicles built prior to 12/1/2001 may exhibit the following shift and engagement conditions: ^ No 2nd Gear ^ No 3rd Gear ^ No Engine Braking In Manual 1st. Out of specification pressures controlled by the transmission main control valve body separator plate may be the cause. ACTION Verify the condition, the main control valve body separator plate may need to be updated to the latest level. Refer to the following Service Procedure for details. SERVICE PROCEDURE Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 03-22-10 > Nov > 03 > A/T - No 2nd, 3rd Gear/No Engine Braking/DTC's Set > Page 5678 CAUTION A NEW SEPARATOR 7Z490 MUST BE USED WHEN INSTALLING THE SPECIAL SERVICE KIT 7M203 OR ADDITIONAL TRANSMISSION DAMAGE MAY OCCUR. REFER TO THE PARTS APPLICATION CHART IN THIS ARTICLE FOR CORRECT SEPARATOR PLATE PART LISTING. NOTE THIS ARTICLE DOES NOT APPLY TO ANY OTHER CONDITIONS OR COMPONENTS THAT MAY CAUSE SIMILAR SYMPTOMS AND IS ONLY WRITTEN TO COVER THESE SPECIFIC CONDITIONS. NOTE AN IN-LINE SERVICE FILTER IS NOT REQUIRED TO BE ADDED OR REPLACED FOR THIS TSB. 1. Verify that one or more of the following conditions exist. ^ Low Line Pressure While In Drive At WOT ^ No 2nd And/Or No 3rd Gear Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 03-22-10 > Nov > 03 > A/T - No 2nd, 3rd Gear/No Engine Braking/DTC's Set > Page 5679 ^ No Engine Braking In Manual 1st ^ DTC P0732, P0733 Or P1762 2. Install kit (3L5Z-7M203-JA) to update the main control valve body assembly, refer to the installation procedures found in the kit. 3. Reinstall the main control by continuing to follow the installation steps listed in the Workshop Manual, in-vehicle service, main control valve body. 4. After completing the procedure, verify the condition has been corrected. 5. Clear all DTCs. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-11-9, 02-13-8 02-08-2 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 032210A Replace Separator Plate 2.8 Hrs. And Update Main Control Valve Body (Includes Time To Remove And Install Main Control Valve Body And Diagnosis) DEALER CODING CONDITION BASIC PART NO. CODE D100 D8 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 01-22-3 > Nov > 01 > A/T - Buzzing Noise When Torque Converter Engaged Valve Body: All Technical Service Bulletins A/T - Buzzing Noise When Torque Converter Engaged Article No. 01-22-3 11/12/01 ^ NOISE - BUZZING NOISE FROM THE TRANSMISSION WHEN THE TORQUE CONVERTER IS ENGAGED - VEHICLES PRODUCED 11/15/2000 THROUGH 11/11/2001 EQUIPPED WITH 4.6L ENGINE AND 5R55W TRANSMISSION ONLY ^ TRANSMISSION - 5R55W - BUZZING NOISE FROM THE TRANSMISSION WHEN THE TORQUE CONVERTER IS ENGAGED - VEHICLES PRODUCED 11/15/2000 THROUGH 11/11/2001 EQUIPPED WITH 4.6L ENGINE ONLY FORD: 2002 EXPLORER MERCURY: 2002 MOUNTAINEER ISSUE Some vehicles built prior to 11/11/2001 equipped with 5R55W and 4.6L engine, may exhibit a buzzing noise when the torque converter is engaged and the transmission fluid temperature is between 38-66°C (100-150 °F). This may be caused by a high velocity of fluid flow in the Main Control. ACTION Verity that the condition exists using the procedure listed. If the conditions described are verified, the Main Control will need to be replaced. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE THIS ARTICLE DOES NOT APPLY TO ANY OTHER CONDITIONS OR COMPONENTS THAT MAY CAUSE SIMILAR SYMPTOMS. 1. To verity that the condition exists with the vehicle, first connect a tachometer to the engine if the vehicle is not already equipped. 2. Install an NGS or equivalent and monitor the Transmission Fluid Temperature (TFT). 3. Start the engine and drive the vehicle. 4. When the TFT reaches 38°C (100 °F), maintain a constant speed of about 80 km/h (50 mph) to engage the converter. Tap the brake pedal with the left foot. Engine RPM should increase when the brake pedal has been tapped, and decrease after about five seconds after the pedal is released. 5. Maintaining a constant vehicle speed, allow the torque converter to re-engage. 6. Listen for the Torque Converter Clutch buzzing noise. Is the noise present? ^ If yes, continue with the verification. ^ If no, follow normal diagnosis as listed in the Workshop Manual, the Main Control is not the problem. 7. Continue to bring the transmission to operating temperature above 66°C (150°F). This may be accomplished by driving the vehicle for 15 to 20 minutes. 8. After normal operating temperature is reached, maintain a constant speed of about 80 km/h (50 mph) to engage the converter. Tap the brake pedal with the left foot. Engine RPM should increase when the brake pedal has been tapped, and decrease after about five seconds after the pedal is released. 9. Maintaining a constant vehicle speed, allow the torque converter to re-engage. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 01-22-3 > Nov > 01 > A/T - Buzzing Noise When Torque Converter Engaged > Page 5684 10. Listen for the Torque Converter Clutch buzzing noise. Has the noise disappeared? ^ If yes, continue. ^ If no, follow normal diagnosis as listed in the Workshop Manuals, the Main Control is not the problem. 11. If the condition exists, drain the transmission fluid from the pan. NOTE AN IN-LINE SERVICE FILTER IS NOT REQUIRED TO BE ADDED OR REPLACED FOR THIS ARTICLE. 12. Replace the Main Control 1L2Z-7A100-CA and Fluid Filter 1L2Z-7A098-AC. Follow the steps listed in the Workshop Manual, In-Vehicle Service, Main Control Valve Body, to remove and replace. 13. Verify the condition has been corrected. 14. Clear all DTCs. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 012203A Verify Conditions And 2.6 Hrs. Replace Transmission Main Control DEALER CODING CONDITION BASIC PART NO. CODE 7A100 42 OASIS CODES: 504000, 702000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 01-20-7 > Oct > 01 > A/T - 5R55W Ticking Noise Valve Body: All Technical Service Bulletins A/T - 5R55W Ticking Noise Article No. 01-20-7 10/15/01 ^ NOISE -"TICK" NOISE FROM TRANSMISSION FRONT OR INTERMEDIATE SERVO COVER AREA - VEHICLES EQUIPPED WITH 5R55W TRANSMISSION - VEHICLES PRODUCED PRIOR TO 9/6/2001 ^ TRANSMISSION - 5R55W -"TICK" NOISE FROM TRANSMISSION FRONT OR INTERMEDIATE SERVO COVER AREA - VEHICLES PRODUCED PRIOR TO 9/6/2001 FORD: 2002 EXPLORER MERCURY: 2002 MOUNTAINEER ISSUE Some vehicles produced before 9/6/2001 equipped with the 5R55W transmission, may exhibit a tick noise emanating from the Front or Intermediate Servo Cover. This tick noise is only present at Idle in Park or Neutral. ACTION Verify that the condition exists and the noise is emanating from the Front or Intermediate Servo. If so, the Separator Plate 7Z490 or the Main Control may need to be replaced. Follow the service procedures for the repair. SERVICE PROCEDURE This TSB does not apply to any other ticking noises from transmission and vehicle components or locations. NOTE DO NOT ADD THE IN-LINE SERVICE FILTER AS LISTED IN THE WORKSHOP MANUAL. THE IN-LINE FILTER IS NOT REQUIRED TO BE ADDED FOR THIS TSB. 1. Verify that the condition exists ONLY during the following conditions: - at Idle, - while in Park and Neutral, - with the noise emanating from the Front or Intermediate Servos. 2. If the condition exists, drain the transmission fluid from the pan. 3. Remove the fluid pan and fluid pan gasket (the gasket is reusable). 4. Inspect the fluid in pan for major contamination. If major contamination is present, the Main Control (7A100) and Fluid Filter will need to be replaced. 5. If major contamination is not present, only the Main Control Separating Plate and fluid filter need to be replaced. 6. To replace ONLY the Main Control (7A100) and Fluid Filter (7A098), follow the steps listed in the Workshop Manual In-Vehicle Service, Main Control Valve Body, to remove and replace. 7. To replace ONLY the Main Control Separating Plate (7Z490) and Fluid Filter (7A098), follow the removal steps listed in the Workshop Manual In-Vehicle Service, Main Control Valve Body. 8. Once the Main Control Valve Body has been removed, rotate the body so that the separator is up and place on a clean work surface. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 01-20-7 > Oct > 01 > A/T - 5R55W Ticking Noise > Page 5689 9. Remove the three screws that attach the plate to the main control, remove and discard the plate (Figure 1). 10. Make sure that the check balls are in there proper location (Figure 2). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 01-20-7 > Oct > 01 > A/T - 5R55W Ticking Noise > Page 5690 11. lnstall the Special Service Tools 307-334 (2 required) on to the main control (Figure 3). 12. Install a NEW service Separator Plate, install the three (3) screws and tighten to 10 Nm (89 lb-in). Remove the Special Service Tools. 13. Reinstall the Main Control by continuing to follow the Installation steps listed in the Workshop Manual In-Vehicle Service, Main Control Valve Body. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 012007A Replace Main Control 1.8 Hrs. Valve Body And Fluid Filter 012007B Replace Main Control 1.9 Hrs. Valve Body Separator Plate And Fluid Filter DEALER CODING CONDITION BASIC PART NO. CODE 7Z490 42 OASIS CODES: 504000, 597997, 702000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5691 Valve Body: Specifications Main control valve body screws ................................................................................................................................................... 8-11 Nm (71-97 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5692 Valve Body: Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5693 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5694 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5695 Valve Body: Description and Operation Refer to Automatic Transmission/Transaxle / Description and Operation/Automatic Transmission 5R55W/S / Hydraulic System. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly Valve Body: Service and Repair Disassembly and Assembly Main Control Valve Body Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 5698 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 5699 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 5700 Disassembly 1. CAUTION: The SSC solenoid may pop out of its bore. This may damage the solenoid. Remove the SSA and the SSC clamp and SSA and SSC solenoid. 1. Remove the solenoid clamp screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 5701 2. Remove the solenoid clamp. 3. Remove the SSA and SSC solenoids. 2. CAUTION: The torque converter clutch (TCC) solenoid may pop out of its bore. This may damage the solenoid. CAUTION: The converter modulator valve may come out after the TCC solenoid. This may cause damage to the valve. Remove the SSB, SSD, TCC and the EPC solenoid. 1. Remove the solenoid clamp screw. 2. Remove the solenoid clamp. 3. Remove the SSB, SSD, TCC and the EPC solenoids. 3. Rotate the main control valve body so that the main control separating plate is facing up. 4. CAUTION: Valves may come out when rotating the main control valve body. CAUTION: The extension housing lube orifice and relief valves may stick to the separator plate. NOTE: The main control separator plate has a bonded gasket. Remove the valve body separator plate screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 5702 5. Remove valve body separator plate. 6. Remove the extension housing lube orifice. 7. Remove the black plastic converter relief valve and spring. 8. Remove the four main control valve body check balls. 9. If the main control requires cleaning, completely disassemble the main control. Refer to the main control exploded view in this procedure. Assembly 1. CAUTION: Do not lose parts when cleaning or servicing. Thoroughly clean all parts in solvent and blow dry with moisture free compressed air. 2. CAUTION: Do not stone, file or sand the valves. This will remove the anodized finish and may result in further main control or transmission damage. After cleaning the main control valve body, carry out the following: - Inspect all valve and plug bores for scoring or burrs. - Check all fluid passages for obstructions. - Inspect all valves and plugs for burrs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 5703 - Inspect all mating surfaces for burrs or distortion. - Inspect all springs for distortion. - Check all valves and plugs for free movement in their respective bores. - Valves and plugs, when dry, must fall from their own weight into their respective bores. - Roll the manual valve on a flat surface to check for a bent condition. 3. Clean and inspect the EPC solenoid screens. 4. Remove and install new shift solenoid 0-rings. 5. Clean and inspect the TCC solenoid. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 5704 6. Install the four main control valve body check balls. 7. Install the dark color plastic converter relief valve and spring. 8. Install the extension housing lube orifice. 9. NOTE: Apply petroleum jelly on the valve body separator plate to hold it in place on the main control. NOTE: Use new bonded separator plate to main control. Install the main control valve body separator plate to the main control. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 5705 10. Install the special tools into the main control valve body. 11. Tighten the screws. 12. Remove the special tools from the main control valve body. 13. Rotate the main control valve body so the valve body separator plate is facing down. 14. CAUTION: All solenoid electrical connectors must face upward on installation. NOTE: All shift solenoids are interchangeable. NOTE: If the TCC valve came out during disassembly, use caution when installing the torque converter clutch solenoid. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 5706 Install the SSB, SSD, TCC and EPC solenoids. 1. Install the TCC solenoid. 2. Install the SSB and SSD solenoids. 3. Install the EPC solenoid. 15. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No.204 plug. Install the solenoid clamp and the screw. 1. Position the solenoid clamp on the main control valve body. 2. Install the screw. 16. CAUTION: The shift solenoid electrical terminals must face upon installation. NOTE: The shift solenoids are interchangeable. Install the SSA and the SSC shift solenoids. 17. Install the solenoid clamp and the screw. 1. Position the solenoid clamp on the main control valve body. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 5707 2. Install the screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 5708 Valve Body: Service and Repair Removal and Installation Main Control Valve Body Special Tools Special Tool(s) Removal 1. with the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. If equipped, loosen the nut and position the heat shield out of the way. 3. Drain transmission fluid. - Remove all the transmission fluid pan screws except for two in the front. Loosen the two front transmission fluid pan screws. Pry the rear of the transmission fluid pan down and allow fluid to drain. After fluid is drained remove the front two transmission fluid pan screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 5709 4. Remove the transmission fluid pan. 1. Remove the transmission fluid pan. 2. Remove and discard the transmission fluid pan gasket. 5. Remove and discard the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 6. Unclip main control valve body wire harness. - Lift up on wire harness guide and protector and disengage the retaining pins from the solenoid clamps. 7. Disconnect the six solenoid electrical connectors. 1. Disconnect the SSA, SSB, SSC and SSD electrical connectors. 2. Disconnect the torque converter clutch (TCC) solenoid electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 5710 3. Disconnect the electronic pressure control (EPC) solenoid electrical connector. 8. Remove the manual control valve detent lever spring. 1. Remove the manual control valve detent lever spring screw. 2. Remove the manual control valve detent lever spring. 9. Remove the low/reverse servo. 1. Remove the low/reverse servo cover screws. 2. Remove the low/reverse band servo cover and gasket. Discard the low/reverse servo separator plate cover gasket. 10. Remove the low/reverse band servo piston and rod. 11. CAUTION: Support the main control valve body. Do not remove the two (gold) screws specified. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 5711 12. CAUTION: Support the main control valve body. Remove the screws. 13. Remove the main control valve body. Installation 1. Install the special tool into the transmission case. 2. Position the main control valve body with the two special tools as a guide. 3. NOTE: The main control valve body screws will be tightened in later steps. Loosely install four M6 x 45 mm (1.8 inch) screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 5712 4. NOTE: The main control valve body screws will be tightened in later steps. Loosely install two M6 x 35 mm (1.4 inch) screws. 5. Remove the special tools. 6. NOTE: The main control valve body screws will be tightened in later steps. Loosely install the M6 x 30 mm (1.2 inch) screw. 7. NOTE: The main control valve body screws will be tightened in later steps. Loosely install the sixteen M6 x 40 mm (1.6 inch) main control valve body screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 5713 8. Tighten the main control valve body screws in the sequence shown. 9. Rotate the manual lever into the NEUTRAL position. 10. Install the manual control valve detent lever spring. 11. Install the low/reverse band servo piston and rod. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 5714 12. Install the low/reverse band servo cover. 1. Install the low/reverse band servo cover and gasket. 2. Loosely install the low/reverse servo piston cover screws. 13. Tighten the servo cover screws in the sequence shown. 14. Connect the six solenoid electrical connectors. 1. Connect SSA, SSB, SSC, and SSD electrical connectors. 2. Connect the Torque Converter Clutch (TCC) solenoid electrical connector. 3. Connect the Electronic Pressure Control (EPC) solenoid electrical connector. 15. CAUTION: Excessive pressure may break the locating pins. Install the main control valve body wire harness. - Align the retaining pins to the holes in the solenoid clamps and press in the main control valve body wire harness guide and protector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 5715 16. Install the transmission fluid filter. 1. Install the transmission fluid filter. 2. Install the transmission fluid filter screw. 17. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Install and align the transmission fluid pan. 18. Tighten the transmission fluid pan screws. - Tighten the transmission fluid pan screws in a crisscross sequence. 19. If equipped, position the servo heat shield over the servos and clip it to the pan rail. 20. NOTE: Start with a minimum of 3.7 liters (4 quarts) of clean automatic transmission fluid. Fill transmission with clean automatic transmission Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 5716 fluid to the correct fluid level. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Specifications Clutch Disc: Specifications O.S. Diameter (approximately) ............................................................................................................ ................................................... 258 mm (10.2 inch) I.S. Diameter (approximately) .......................... ........................................................................................................................................... 173 mm (6.8 oz) Facing area sq ........................................................................................................................ ................................................................ 288 cm (45 sq. inch) Compressed thickness ...................... ...................................................................................................................................................... 7.8 mm (0.307 inch) Lining material .......................................................................................................... ............................................................................ Woven non-asbestos Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Specifications > Page 5721 Clutch Disc: Service and Repair Disc and Pressure Plate Special Tool(s) Removal 1. Remove the transmission. 2. CAUTION: If the clutch disc and pressure plate are to be reinstalled, bolts must be removed evenly or permanent damage to the diaphragm spring will occur resulting in complete clutch release. Remove the bolts, clutch pressure plate and the clutch disc. If the parts are to be reused, index-mark the clutch pressure plate to the flywheel. Installation 1. Lubricate the transmission input shaft pilot bearing. - Use front axle grease. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Specifications > Page 5722 2. Adjust the clutch pressure plate. 1 Using a suitable press, press downward on the fingers until the adjusting ring moves freely. 2 Rotate the adjusting ring counterclockwise to compress the tension springs. Hold the adjusting ring in this position. 3 Release the pressure on the fingers. The adjusting ring will stay in the reset position. 3. Using the special tool, position the clutch disc on the flywheel. 4. NOTE: If reusing the clutch pressure plate and flywheel, align the marks made during removal. Using the special tool, align the clutch disc and the clutch pressure plate. Install the bolts and tighten in a star pattern sequence. 5. Install the transmission. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Specifications Clutch Fluid: Specifications High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB 3ESA-M6C25-A Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid Reservoir > Component Information > Service and Repair Clutch Fluid Reservoir: Service and Repair "For information regarding this component please refer to clutch master cylinder service and repair" Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Specifications Clutch Master Cylinder: Specifications Clutch master cylinder reservoir bolts .................................................................................................................................................. 2.2 Nm (18 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Specifications > Page 5733 Clutch Master Cylinder: Service and Repair Clutch Master Cylinder/Reservoir Special Tool(s) Removal and Installation 1. Raise and support the vehicle. 2. Using the special tool, disconnect the hydraulic line from the clutch slave cylinder. 3. Lower the vehicle. 4. Disconnect the Clutch Pedal Position (CPP) switch electrical connector. 5. Disconnect the clutch master cylinder rod from the clutch pedal arm. - Remove and discard the clutch master cylinder push rod bushing. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Specifications > Page 5734 6. Remove the CPP switch. - Pinch the lock tabs and pull the clip forward. - Rotate and snap the CPP switch from the clutch master cylinder rod. 7. Remove the reservoir. 8. Remove the three pushpins, four bolts, four screws and the inner fender splash shield. 9. Unclip the hydraulic line-to-frame retainer. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Specifications > Page 5735 10. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, wash the surface with water immediately. Unlock and remove the clutch master cylinder assembly. Twist the clutch master cylinder clockwise 45 degrees to unlock it from the support bracket. - Remove the reservoir, the hydraulic line and the clutch master cylinder as an assembly. - Install a new clutch master cylinder push rod bushing. 11. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, wash the surface with water immediately. To install, reverse the removal procedure. Bleed the clutch hydraulic system. - Rotate the clutch master cylinder 45 degrees counterclockwise. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Specifications Clutch Slave Cylinder: Specifications Clutch slave cylinder bolts ................................................................................................................... ..................................................... 20 Nm (15 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Specifications > Page 5739 Clutch Slave Cylinder: Service and Repair Slave Cylinder Removal 1. Remove the transmission. 2. NOTE: Inspect the clutch housing for traces of fluid. If brake fluid is visible, install a new clutch slave cylinder. Remove the clutch slave cylinder. 1 Remove the bolts. 2 Remove the clutch slave cylinder. 3. Inspect the clutch slave cylinder for the following: - Worn or damaged boot. - Leaking fluid. - Worn or damaged bearing. 4. Inspect the clutch release bearing as follows: - Rotate the outer race while applying pressure. If the bearing rotation is rough, install a new clutch slave cylinder. - Inspect for wear or damage. If wear pattern is continuous (not segmented) and the wear appears to be deep in bearing face, install a new clutch slave cylinder. Installation 1. To install, reverse the removal procedure. - Position the clutch slave cylinder to the transmission and install the bolts. 2. Install the transmission. 3. Bleed the clutch hydraulic system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Tools and Equipment Hydraulic Hose: Tools and Equipment Clutch Line Fork AST tool# 8008 Used for the R and R of the hydraulic clutch line from the internally mounted slave cylinder. This tool is applicable to the following Ford vehicles with manual transmissions: 1989 and later Ford Aerostar, Bronco II, Explorer, F150 and Ranger. - For R and R of Hydraulic Clutch Lines - Applicable to Ford Models with Manual Transmissions - Steel Construction - Black-Oxide Finish Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Service and Repair Clutch Pedal Assembly: Service and Repair Clutch Pedal Removal and Installation NOTE: The clutch pedal is serviced with the brake pedal as an assembly only. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Diagrams Connector View C257 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Service and Repair Pilot Bearing: Service and Repair Bearing Special Tools Special Tool(s) Removal 1. Using the special tool, remove the transmission input shaft pilot bearing. 2. Inspect the transmission input shaft pilot bearing for: - misalignment and looseness in the flywheel. - needle rollers for scoring, worn or broken needle rollers, inadequate grease or discoloration. - seal leakage. Installation Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Service and Repair > Page 5752 1. NOTE: The transmission input shaft pilot bearing can only be installed with the seal facing the transmission. The transmission input shaft pilot bearing is pregreased and does not require additional lubrication. A new transmission input shaft pilot bearing must be installed whenever it is removed. Using a soft-face hammer and the special tool, install the transmission input shaft pilot bearing. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Mechanical Specifications Pressure Plate: Mechanical Specifications Clutch pressure plate bolts .................................................................................................................. ...................................................... 32 Nm (24 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Mechanical Specifications > Page 5757 Pressure Plate: Pressure, Vacuum and Temperature Specifications Total plate pressure ............................................................................................................................. .................................................... 8500 kg (1,900 lbs) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Page 5758 Pressure Plate: Service and Repair "For information regarding this component please refer to clutch disc service and repair" Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Specifications Differential Case: Specifications 8.8-Inch Ring Gear Maximum differential case runout ........................................................................................................ ......................................................... 0.076 (0.003) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Differential Case Differential Case: Service and Repair Differential Case Differential Case Special Tool(s) Removal 1. Remove the driveshaft. 2. Remove the axle shafts. 3. Wipe the lubricant from the internal working parts and inspect the parts for wear and damage. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Differential Case > Page 5765 4. Rotate the differential assembly to check for roughness indicating bearing/gear damage. 5. Using a suitable dial indicator and the special tool, measure and record the differential ring gear backlash between teeth in four opposing places. 6. CAUTION: Mark the position of the bearing caps, as the arrows may not be visible. Always install the bearing caps in their identical locations and positions. Remove the bearing caps. 1 Remove the bolts. 2 Remove the bearing caps. 7. WARNING: Do not allow the differential assembly to fall. CAUTION: Place a wood block between the pry bar and the differential housing to protect the machined surface from damage. Using a pry bar and a wood block, remove the differential assembly from the differential housing. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Differential Case > Page 5766 8. Remove the bolts. 9. CAUTION: Do not damage the differential ring gear bolt hole threads. CAUTION: If removing the anti-lock speed sensor ring, discard it, and install a new anti-lock speed sensor ring during installation. Insert a punch in the bolt holes, and drive off the differential ring gear and, if necessary, the anti-lock speed sensor ring. 10. If the differential ring gear backlash variation between teeth measurement, taken at the beginning of this procedure, did not exceed the specification, proceed to Step 14. If the differential ring gear backlash variation between teeth measurement, taken at the beginning of this procedure, exceeded the specification, the cause may be a warped differential ring gear, differential case/differential bearing damage. Proceed as follows to verify the cause of the excessive runout. 11. NOTE: Visually inspect the differential bearing cups and cones for discoloration indicating bearing overheating or failure. Position the differential assembly, including the differential bearing cups and all the differential bearing shims as removed, in the differential housing. Install the bearing caps and the bolts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Differential Case > Page 5767 12. Position the special tool. 1 Rotate the differential case to verify that the differential bearings have seated correctly. 2 Position the special tool. 3 Make sure there is no differential case endplay. 13. Measure and note the differential case runout. - If the runout does not exceed the specification, install a new differential ring gear and pinion. - If the runout exceeds the specification, the differential ring gear is true and the concern is due to differential case damage. Install a new differential case. 14. Using the special tools, remove the differential bearings. Installation All vehicles 1. Using the special tool, install the differential bearings. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Differential Case > Page 5768 2. CAUTION: If installing a new anti-lock speed sensor ring, align the notch on the case flange and the tab on the anti-lock speed sensor ring. Position the differential ring gear, the anti-lock speed sensor ring, and the differential case. Align the bolt holes by starting two bolts through the holes in the differential case and the differential ring gear. Press the new anti-lock speed sensor ring, if removed, and the differential ring gear on the differential case. 3. Install the bolts. - Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to the bolt threads. 4. With the pinion depth set and pinion installed, place the differential assembly in the differential housing. 5. Install a differential bearing shim on the left side. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Differential Case > Page 5769 6. CAUTION: Always install the bearing caps in their identical locations and positions. NOTE: Apply pressure toward the left side to make sure the left differential bearing cup seats correctly. Install the left bearing cap and loosely install the bolts. 7. Install progressively larger differential bearing shims on the right side until the largest shim selected can be installed by hand. 8. Install the right side bearing cap and tighten the left side and right side bolts to specification. 9. Rotate the differential case to make sure it turns freely. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Differential Case > Page 5770 Measuring backlash 10. Using the special tools, measure and note the differential ring gear backlash. - If backlash is within the specification, refer to Backlash within specification. For the allowable range, refer to Specifications. - If a zero backlash condition occurs, refer to Zero backlash. - If backlash is not within the specification, refer to Backlash not within specification. Zero backlash 11. If a zero backlash condition occurs, add 0.51 mm (0.020 inch) to the RH side and subtract 0.51 mm (0.020 inch) from the LH side to allow backlash indication. Measure the backlash. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Differential Case > Page 5771 Backlash not within specification 12. To increase or decrease backlash, remove the bearing caps and install a thicker shim and a thinner shim accordingly. - If backlash is not within the specification, increase the thickness of one differential bearing shim and decrease the thickness of the other differential bearing shim by the same amount. 13. Rotate the differential assembly several times to verify that the differential bearings seated correctly. 14. Using the special tools, recheck the backlash. - If backlash is within the specification, refer to Backlash within specification. If backlash is not within the specification, repeat Backlash not within specification. Backlash within specification 15. Remove the bolts and the bearing caps. 16. To establish differential bearing preload, increase both left and right differential bearing shim sizes by the specification shown. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Differential Case > Page 5772 17. Using the special tool, fully seat the differential bearing shims. Make sure the assembly rotates freely. 18. Install the bearing caps and bolts. 19. Using the special tools, recheck the backlash. 20. Install the axle shafts. 21. Install the driveshaft. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Differential Case > Page 5773 Differential Case: Service and Repair Differential Case and Ring Gear-Conventional Differential Case and Ring Gear-Conventional Special Tools Special Tool(s) Disassembly 1. Remove the differential assembly from the differential housing. 2. Remove the bolts. 3. CAUTION: Do not damage the differential ring gear bolt hole threads. CAUTION: If removing the anti-lock speed sensor ring, discard it, and install a new anti-lock speed sensor ring during assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Differential Case > Page 5774 Insert a punch in the bolt holes, and drive off the differential ring gear and, if necessary, the anti-lock speed sensor ring. 4. Using the special tools, remove the differential bearings, if necessary. 5. Remove the bolt. 6. Remove the differential pinion shaft. 7. Rotate and remove the differential pinion gears and differential pinion thrust washers. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Differential Case > Page 5775 8. Remove the differential side gears and differential side gear thrust washers. Assembly 1. Lubricate the differential side gear thrust washers and the differential side gear journals. - Use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. 2. Position the differential side gear thrust washers on the differential side gears. 3. Position the differential side gear and thrust washer assemblies in the differential case. 4. Lubricate and assemble the differential pinion thrust washers and differential pinion gears. - Use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Differential Case > Page 5776 5. Engage the differential pinion gears opposite the differential side gears. 6. Rotate the differential pinion gears to align with the differential pinion shaft bore. 7. Insert the differential pinion shaft. - Align the bolt hole in the differential pinion shaft with the bolt hole in the differential case. 8. NOTE: If a new bolt is unavailable, coat the threads with Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5 prior to installation. Install a new bolt finger-tight. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Differential Case > Page 5777 9. Using the special tool, install the new differential bearings. 10. CAUTION: If installing a new anti-lock speed sensor ring, align the notch on the case flange and the tab on the anti-lock speed sensor ring. Position the differential ring gear, the anti-lock speed sensor ring, and the differential case. Align the bolt holes by starting two bolts through the holes in the differential case and the differential ring gear. Press the new anti-lock speed sensor ring, if removed, and the differential ring gear on the differential case. 11. Install the bolts. - Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to the bolt threads. 12. Install the differential assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Differential Case > Page 5778 Differential Case: Service and Repair Differential Case and Ring Gear-Traction-LOK Differential Case and Ring Gear-Traction-Lok Special Tools Special Tool(s) Disassembly 1. Remove the differential assembly from the differential housing. 2. Remove the bolts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Differential Case > Page 5779 3. CAUTION: Do not damage the bolt hole threads. CAUTION: If removing the anti-lock speed sensor ring, discard it, and install a new anti-lock speed sensor ring during assembly. Insert a punch in the bolt holes, and drive off the differential ring gear and, if necessary, the anti-lock speed sensor ring. 4. Using the special tools, remove the differential bearings. 5. Remove the bolt and remove the differential pinion shaft. 6. WARNING: Due to the spring tension, use care when removing the differential clutch spring. Failure to follow these instruction can result in personal injury. Remove the differential clutch spring. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Differential Case > Page 5780 7. Remove the differential gears. 1 Remove the two differential pinion gears. 2 Remove the two differential side gears. 3 Remove the two differential pinion thrust washers. 8. CAUTION: Keep the differential clutch packs in order. Do not mix them. Always reassemble them in the same sequence. Separate the differential clutch packs and shims from the differential side gears, and tag them "right" and "left." Clean and inspect the remaining differential components for wear and damage and install new parts as necessary. 9. CAUTION: Do not use acids or solvents when cleaning the differential clutch packs. Wipe the components only with a clean, lint-free cloth. Clean and inspect the differential clutch packs for wear and damage and install new parts as necessary. Assembly Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Differential Case > Page 5781 1. CAUTION: 118 ml (4 oz) of the Additive Friction Modifier must be used in the axle. Lubricate each steel clutch plate and soak all the friction plates for no less than 15 minutes. Use Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A 2. CAUTION: Do not mix the clutch plates, clutch discs or shim from one side with the other. Assemble the differential clutch packs (without the shims) on their respective differential side gear. 3. CAUTION: Use the correct mandrel with the special tool. Place the base portion of the special tool in a vise. Install the differential side gear and differential clutch pack (without the shim) on the tool. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Differential Case > Page 5782 4. Position the special tool hand-tight on top of the differential clutch pack. 5. Install the special tool over the disc and differential clutch pack. 6. Install the nut. 7. Select and insert the thickest feeler gauge blade that will enter between the tool and the differential clutch pack. The reading will be the thickness of the new clutch shim. Selective Shims 8. Remove the special tool from the differential clutch pack and differential side gear assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Differential Case > Page 5783 9. Install the shim(s) on the differential clutch pack and differential side gear assembly. 10. Install the differential side gear assemblies in the differential case. 11. Install the differential pinion gear and differential pinion thrust washer assemblies in the differential case. 12. Using a soft-faced hammer, install the differential clutch spring. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Differential Case > Page 5784 13. NOTE: If a new bolt is unavailable, coat the threads with Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5 prior to installation. Install the differential pinion shaft and install a new bolt finger-tight. 14. Mount the differential case and the special tool in a vise. Using the special tool, check the torque necessary to rotate one differential side gear. - If reusing the original clutch plates, the initial minimum break-away torque must be no less than the specification. The minimum rotating torque necessary to keep the differential side gear turning with new clutch plates may vary. 15. Using the special tool, install the differential bearings. 16. CAUTION: If installing a new anti-lock speed sensor ring, align the notch on the case flange and the tab on the anti-lock speed sensor ring. Position the differential ring gear, the anti-lock speed sensor ring, and the differential case. Align the bolt holes by starting two bolts through the holes in the differential case and the differential ring gear. Press the new anti-lock speed sensor ring, if removed, and the differential ring gear on the differential case. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Differential Case > Page 5785 17. Install the bolts. - Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to bolt threads. 18. Install the differential assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Specifications Differential Cover: Specifications 8.8-Inch Ring Gear Differential housing cover bolt ............................................................................................................................................................. 45 Nm (33 ft. lbs.) Front Drive Axle/Differential Dana 35 Differential housing cover-to-differential housing bolts ....................................................................................................................... 22 Nm (16 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Specifications > Page 5789 Differential Cover: Service and Repair Differential Housing Cover Removal 1. Position the vehicle on a hoist. Place vehicle in neutral. 2. Remove the differential housing cover. 1 Remove the bolts and drain the lubricant from the differential housing. 2 Remove the differential housing cover. Installation 1. CAUTION: The machined surfaces on the differential housing and the differential housing cover must be clean and free of oil before applying the silicone sealant. Cover the inside of the rear axle prior to cleaning the machined surface to prevent contamination. Clean the gasket mating surfaces. 2. CAUTION: Install the differential housing cover within 15 minutes of applying the silicone, or it will be necessary to apply new sealant. Apply a continuous bead of sealant to the differential housing cover. Use Clear Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specification ESB-M4G92-A. 3. NOTE: If possible, allow one hour before filling the axle with lubricant to allow the silicone sealant to cure. Install the differential housing cover. 1 Position the differential housing cover. 2 Install the bolts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Specifications > Page 5790 4. CAUTION: For Traction-Lok axles, first fill the rear axle with 118 ml (4 oz) of Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A. NOTE: Service refill capacities are determined by filling the rear axle to the level shown. Fill the rear axle with 2.4 liters (5.0 pints) of lubricant and install the fill plug. For conventional axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. - For Traction-Lok axles, use SAL 75W-140 Synthetic Rear Axle Lubricant FITZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 5. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair Differential Axle Housing: Service and Repair Axle Housing Removal and Installation 1. NOTE: Make sure the parking brake control is fully released. Release the tension on the front parking brake cable and conduit. 1 Pull on the front parking brake cable and conduit until the parking brake pedal moves. 2 Insert a suitable retainer, such as a 5/32 inch drill bit, into the parking brake control to hold it in place so that the front parking brake cable and conduit stays slack. 2. Raise and support the vehicle. 3. Remove the axle shafts. 4. Mark the driveshaft flange and pinion flange for correct alignment during installation. 5. CAUTION: The driveshaft centering socket yoke fits tightly on the rear pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the yoke from the flange. Pry only in the area shown with a suitable tool to disconnect the yoke from the flange. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Page 5794 Remove the four driveshaft retainer bolts and disconnect the driveshaft. Wire the driveshaft out of the way. 6. NOTE: Do not disconnect the brake lines from the brake hose junction block. NOTE: Explorer Sport Trac is shown. Explorer Sport brake hose junction block is located on the LH side of the differential housing. Disconnect the brake hose junction block from the differential housing. 7. Disconnect the vent hose. 8. Disconnect the parking cable and conduit at the parking brake lever, if so equipped. 9. Disconnect the vehicle speed sensor, if so equipped. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Page 5795 10. CAUTION: Pull the brake lines from the retaining clips. Remove the brake system. Disconnect the rear brake drum backing plates, if equipped, and wire them out of the way. - Remove the rear brake discs and the rear disc brake calipers and wire the rear disc brake calipers aside. 11. Position a suitable jack under the rear axle housing and strap it securely in place. 12. Disconnect the rear stabilizer bar at the links. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Page 5796 13. Remove the lower shock absorber nuts and bolts, and the front dampener shock absorber nuts and bolts, if equipped. 14. Remove the rear axle U-bolt assembly. 15. CAUTION: Be careful of obstructions and of causing damage to vehicle components when performing this step. Raise the differential housing off the rear springs and manipulate the differential housing from the vehicle. 16. CAUTION: Be sure to align the driveshaft flange and the pinion flange index-marks. CAUTION: The driveshaft centering socket yoke fits tightly on the rear axle pinion flange pilot. To ensure that the yoke seats squarely on the flange, tighten the bolts evenly in a cross pattern as shown. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fill Plug, Differential > Component Information > Specifications Fill Plug: Specifications 8.8-Inch Ring Gear Filler plug ............................................................................................................................................. ................................................ 30 Nm (22 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Differential Oil Capacity Front Axle ............................................................................................................................................ ......................................................................... 1.5L Rear Axle Conventional Axle ............................................................................................................... ................................................................. 2.60 liters (5.5 pints) Trac-Lock ......................................... ................................................................................................................................................... 2.5 liters (5.25 pints) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 5804 Fluid - Differential: Fluid Type Specifications Differential Fluid Type Rear Axle Type .......................................................................................................................... SAE 80W-90 Premium Rear Axle Lubricant (conventional rear axles) Type ................................................................................................................................ SAE 75W-140 High Performance Rear Axle (Traction-Lok rear ) Front Axle Type ................................................................................................................................... ............................... SAE 80W-90 Premium Rear Axle Lubricant Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Specifications Pinion Bearing: Specifications 8.8-Inch Ring Gear Differential bearing cap bolt ................................................................................................................. ............................................... 105 Nm (77 ft. lbs. Pinion bearing preload (used pinion bearings) ....................................................................................................................... 0.9-1.5 Nm (8-14 inch lbs.) Pinion bearing preload (new pinion bearings) ...................................................................................................................... 1.8-3.3 Nm (16-29 inch lbs.) Front Drive Axle/Differential Dana 35 Differential bearing cap-to-differential housing bolts ........................................................................................................................... 61 Nm (45 ft. lbs.) Pinion bearing preload (new pinion bearings) ......................................................................................................................... 1.7-3.4 Nm (15-30 lb inch) Pinion bearing preload (original pinion bearings) ............................................................................................................................................................. .............................................................................................................................................................. . The reading must be 0.56 Nm (5 inch lbs.) more .............................................................................................................................................................. than the initial reading taken during disassembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair Pinion Flange: Service and Repair Drive Pinion Flange and Drive Pinion Seal Special Tool(s) Removal 1. Remove the rear wheel and tire assemblies. 2. CAUTION: Remove the brake drums or brake discs to prevent brake drag during drive pinion bearing preload adjustment. Remove the brake system. 3. CAUTION: Index-mark the driveshaft flange and pinion flange for correct alignment during installation. Remove the four bolts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Page 5811 4. CAUTION: The driveshaft centering socket yoke fits tightly on the rear axle pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the yoke from the flange. Pry only in the area shown with a suitable tool to disconnect the yoke from the flange. Using a suitable tool as shown, disconnect the driveshaft centering socket yoke from the rear axle pinion flange. 5. Install a Nm (inch-pound) torque wrench on the nut and record the torque necessary to maintain rotation of the pinion through several revolutions. 6. CAUTION: Discard the nut after removing it. Install a new nut during installation. Use the special tool to hold the pinion flange while removing the nut. 7. Index-mark the pinion flange and the drive pinion stem for correct alignment during installation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Page 5812 8. Using the special tool, remove the pinion flange. 9. Using a screwdriver, force the rear axle drive pinion seal metal flange up and strike it with a hammer. 10. Using gripping pliers and a hammer, remove the seal. Installation 1. Coat the new rear axle drive pinion seal lips with lubricant. 1 Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specifications ESA-M1C75-B. 2. CAUTION: Installation without the correct tool can result in early seal failure. CAUTION: If the rear axle drive pinion flange becomes misaligned during installation, remove the seal and install a new seal. Using the special tool, install the rear axle drive pinion seal. 3. Lubricate the pinion flange splines. - For conventional axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. - For Traction-Lok axles, use SAE 75W-140 Synthetic Rear Axle Lubricant FITZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Page 5813 4. NOTE: Disregard the index marks if installing a new pinion flange. Position the pinion flange. 5. Using the special tool, install the pinion flange. 6. Position the new nut. 7. CAUTION: Do not under any circumstance loosen the nut to reduce preload. If it is necessary to reduce preload, install a new collapsible spacer and nut. CAUTION: Remove the special tool while taking preload readings with the Nm (inch-pound) torque wrench. Use the special tool to hold the pinion flange while tightening the nut. Rotate the pinion occasionally to make sure the differential pinion bearings seat correctly. Take frequent differential pinion bearing preload readings by rotating the pinion with a Nm (inch-pound) torque wrench. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Page 5814 - If the preload recorded prior to disassembly is lower than the specification for used bearings, then tighten the nut to specification. If the preload recorded prior to disassembly is higher than the specification for used bearings, then tighten the nut to the original reading as recorded. 8. CAUTION: Align the Index-marks. Install the four bolts. 9. CAUTION: The driveshaft centering socket yoke fits tightly on the rear axle pinion flange pilot. To ensure that the yoke seats squarely on the flange, tighten the bolts evenly in a cross pattern as shown. Tighten to specification. 10. Install the brake system. 11. Install the rear wheel and tire assemblies. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Specifications Pinion Gear: Specifications 8.8-Inch Ring Gear Differential pinion shaft lock bolt ......................................................................................................................................................... 30 Nm (22 ft. lbs.) Maximum pinion runout ............................................................................................... ................................................................... 0.25 mm (0.010 inch) Front Drive Axle/Differential Dana 35 Ring gear backlash mm (inch) ..................................................................................................................................................... 0.13-0.20 (0 005-0.008) Maximum backlash variation between points checked mm (inch) ................ .............................................................................................................................................................. ......................... 0.05 (0.002) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Specifications > Page 5818 Pinion Gear: Service and Repair Drive Pinion Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Specifications > Page 5819 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Specifications > Page 5820 Special Tool(s) Removal 1. Remove the differential case. 2. CAUTION: Record the torque necessary to maintain rotation of the drive pinion gear through several revolutions prior to removing the pinion flange. Remove the pinion flange. 3. Using a screwdriver, force the rear axle drive pinion seal metal flange up and strike it with a hammer. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Specifications > Page 5821 4. Using gripping pliers and a hammer, remove the rear axle drive pinion seal. 5. Remove the rear axle drive pinion shaft oil slinger. 6. Using the special tool and a soft-faced hammer, drive the pinion assembly out of the front pinion bearing and remove it through the rear of the differential housing. 7. Remove the drive pinion collapsible spacer and discard it. 8. Using the special tool and a suitable press, remove the pinion bearing. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Specifications > Page 5822 9. NOTE: Do not remove the pinion bearing cups from the differential housing unless the cups are damaged. Using the special tools, remove the outer pinion bearing cup. 10. Using the special tools, remove the inner pinion bearing cup. Installation 1. NOTE: This step and the following step show the preferred method for installing the pinion bearing cups. An alternate method is shown following these two steps. Position the special tools and the inner and outer pinion bearing cups in their respective bores. 1 After placing the inner and outer pinion bearing cups in their bores, place the special tool on the inner pinion bearing cup. 2 Place the special tool on the outer pinion bearing cup. 3 Install the special tool. 2. Tighten the special tool to seat the pinion bearing cups into their bores. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Specifications > Page 5823 3. NOTE: This step and the following step are alternate methods for installing the pinion bearing cups. Carry out these two steps if pinion bearing cup installation was not done in the previous steps. Using the special tools, drive the outer pinion bearing cup into the differential housing. 4. Using the special tools, drive the inner pinion bearing cup into the differential housing. 5. CAUTION: Always install new pinion bearings when installing new pinion bearing cups. NOTE: If the feeler gauge can fit between a cup and the bottom of its bore at any point around the cup, remove and reseat the cup. Check that the cups have seated correctly in their bores. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Specifications > Page 5824 Part 1 of 2 Part 2 of 2 6. NOTE: Apply only a light oil film on the pinion bearings before assembling the tool. Assemble and position the following in the differential housing. 7. NOTE: This step duplicates final pinion bearing preload. Tighten the special tool to the specification shown. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Specifications > Page 5825 8. NOTE: Offset the special tool to obtain an accurate reading. Rotate the special tool several half-turns to make sure the pinion bearings seat correctly and position the special tool as shown. 9. Install the special tool. 1 Position the special tool. 2 Install the bearing caps. 3 Install the bolts. 10. CAUTION: Use only flat, clean drive pinion bearing adjustment shims. CAUTION: Selection of too thick a shim results in a deep tooth contact at final assembly. Do not attempt to force the shim between the Gauge Block and the Gauge Tube. A slight drag indicates correct shim selection. Use a drive pinion bearing adjustment shim as a gauge for shim selection. After determining the correct shim thickness, remove the special tools. 11. Position the correct thickness drive pinion bearing adjustment shim and the pinion bearing on the drive pinion. Using a suitable press and the Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Specifications > Page 5826 special tools, press the pinion bearing until it seats firmly on the pinion. 12. Place a new drive pinion collapsible spacer on the pinion shaft against the pinion stem shoulder. 13. CAUTION: Installation without the correct tool can result in early seal failure. Install a new rear axle drive pinion seal. 1 Install the front pinion bearing. 2 Install the rear axle drive pinion shaft oil slinger. 3 Install the rear axle drive pinion seal on the special tool. 14. CAUTION: If the rear axle drive pinion seal becomes misaligned during installation, remove the seal and install a new seal. NOTE: Coat the rear axle drive pinion seal lips with Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Position the rear axle drive pinion seal in the seal bore, and use the special tool to drive the seal into place. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Specifications > Page 5827 15. From inside the differential housing, install the drive pinion assembly (drive pinion, shims, bearing, and the collapsible spacer) into the carrier bore. 16. Lubricate the pinion flange splines. - For conventional axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. - For Traction-Lok axles, use SAE 75W-140 Synthetic Rear Axle Lubricant FITZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 17. NOTE: Disregard the index marks if installing a new pinion flange. Position the pinion flange. 18. Using the special tool, install the pinion flange. 19. Position the new nut. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Specifications > Page 5828 20. CAUTION: Do not under any circumstance loosen the nut to reduce preload. If it is necessary to reduce preload, install a new collapsible spacer and nut. CAUTION: Remove the special tool while taking preload readings with the Nm (inch-pound) torque wrench. Use the special tool to hold the pinion flange while tightening the nut. Rotate the pinion occasionally to make sure the pinion bearings seat correctly. Take frequent pinion bearing preload readings by rotating the pinion with a Nm (inch-pound) torque wrench. - For new pinion bearings, tighten the nut to specification. - For used pinion bearings, if the preload recorded prior to disassembly is lower than the specification for used bearings, then tighten the nut to specification. - For used pinion bearings, if the preload recorded prior to disassembly is higher than the specification for used bearings, then tighten the nut to the original reading as recorded. 21. Install the differential case in the differential housing. 22. CAUTION: Be sure to align the driveshaft flange and the pinion flange index-marks. Install the four bolts. 23. CAUTION: The driveshaft centering socket yoke fits tightly on the rear axle pinion flange pilot. To ensure that the yoke seats squarely on the flange, tighten the bolts evenly in a cross pattern as shown. Tighten to specification. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Wheel Bearing and Axle Shaft Oil Seal-Drum Brake Axle Bearing: Service and Repair Rear Wheel Bearing and Axle Shaft Oil Seal-Drum Brake Rear Wheel Bearing and Axle Shaft Oil Seal-Drum Brake Special Tool(s) Removal 1. Remove the axle shaft. Special Tools 2. NOTE: If the wheel bearing oil seal is leaking, the differential housing vent may be plugged with foreign material. Using the special tools, remove the rear wheel bearing and wheel bearing oil seal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Wheel Bearing and Axle Shaft Oil Seal-Drum Brake > Page 5834 Installation 1. Lubricate the new rear wheel bearing. - For conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. - For Traction-Lok rear axles, use SAE 75W-140 Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C 192-A. 2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tools, install the wheel bearing oil seal. 5. Install the axle shaft. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Wheel Bearing and Axle Shaft Oil Seal-Drum Brake > Page 5835 Axle Bearing: Service and Repair Rear Wheel Bearing and Axle Shaft Oil Seal-Disc Brake Rear Wheel Bearing and Axle Shaft Oil Seal-Disc Brake Special Tools Special Tool(s) Removal 1. Remove the axle shaft. Special Tools Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Wheel Bearing and Axle Shaft Oil Seal-Drum Brake > Page 5836 2. CAUTION: Never remove the wheel bearing oil seal by itself Always remove the rear wheel bearing and the inner wheel bearing oil seal at the same time. NOTE: If the wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign material. Using the special tools, remove the rear wheel bearing and wheel bearing oil seal together. Installation 1. Lubricate the new rear wheel bearing. - For Traction-Lok rear axles, use SAE 75W-140 Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. - For conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C 197-A. 2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1 C75-B. 4. Using the special tools, install the wheel bearing oil seal. 5. Install the axle shah. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications Axle Shaft: Specifications 8.8-Inch Ring Gear Maximum axle shaft end play ......................................................................................................................................................... 0.762mm (0.030 inch) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 5841 Axle Shaft: Service and Repair Axle Shaft Removal NOTE: In this procedure, drum brake is shown. Disc brake is similar. 1. Raise and support the vehicle. 2. Remove the rear wheel and tire assembly. 3. Remove the brake system. - Remove the brake drum. - Remove the brake discs and rear disc brake calipers. 4. Remove the differential housing cover and drain the lubricant. 5. NOTE: If a new bolt is unavailable, coat the threads with Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5 prior to installation. Remove the differential pinion shaft. 1 Remove and discard the bolt. 2 Remove the differential pinion shaft. 6. CAUTION: Do not damage the rubber O-ring in the U-washer groove. Remove the U-washer. 1 Push the axle shaft inboard. 2 Remove the U-washer. 7. CAUTION: Do not drainage the wheel bearing oil seal. Remove the axle shaft. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 5842 Installation 1. Lubricate the lip of the wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 2. CAUTION: Do not damage the wheel bearing oil seal. Install the axle shaft. 3. CAUTION: Do not damage the rubber O-ring in the U-washer groove. Install the U-washer. 1 Position the U-washer on the button end of the axle shaft. 2 Pull the axle shaft outward. 4. NOTE: If a new bolt is unavailable, coat the threads with Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5 prior to installation. Install the differential pinion shaft. 1 Align the bolt hole in the differential pinion shaft with the bolt hole in the case. 2 Install the new bolt. 5. Install the brake system. - Install the brake drum. - Install the brake discs and calipers. 6. Install the differential housing cover and fill the differential housing with the specified lubricant. 7. Install the rear wheel and tire assembly. 8. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection Wheel Bearing: Testing and Inspection Wheel Bearing Inspection 1. Raise the vehicle until the tire is off the floor. 2. NOTE: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow movement of the tire and wheel assembly. Grasp each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 3. If the tire and wheel (hub) is loose on the wheel spindle or does not rotate freely, perform one of the following actions. ^ On 4x2 vehicles, adjust the front wheel bearings. ^ On 4x4 vehicles, install a new wheel hub. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Companion Flange > Component Information > Specifications Companion Flange: Specifications Bolts retaining the front driveshaft to the front axle pinion flange ........................................................................................................... 18 Nm (13 ft. lbs.) Bolts retaining the driveshaft flange to the rear axle pinion flange ......................................................................................................... 112 Nm (83 ft. lbs.) Bolts retaining the front flange to the transfer case rear output flange ......................................................... ............................................................................................................................................. 103 Nm (76 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Customer Interest for Drive/Propeller Shaft: > 02-22-2 > Nov > 02 > A/T - 5R55E 1st/2nd Gear Whining Noise Drive/Propeller Shaft: Customer Interest A/T - 5R55E 1st/2nd Gear Whining Noise Article No. 02-22-2 11/11/02 ^ NOISE - GEAR WHINE NOISE IN 1ST AND 2ND GEAR ONLY - VEHICLES EQUIPPED WITH 5R55E TRANSMISSION AND 4.0L ENGINE ONLY ^ TRANSMISSION - 5R55E - GEAR WHINE NOISE IN 1ST AND 2ND GEAR ONLY - VEHICLES EQUIPPED WITH 4.0L ENGINE ONLY FORD: 2001-2003 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER ISSUE Some 2001-2003 Rangers, 2001-2003 Explorer Sport/Sport Trac, built prior to 10/18/2002, equipped with a 5R55E automatic transmission and 4.0L engine, may exhibit a gear whine type of noise in 1st and 2nd gear ONLY. This may be caused by the Reverse and Forward Planetary assemblies and/or the driveshaft. ACTION Verify that only these conditions exist and no DTCs are present. If other conditions are present and DTCs exist they must be diagnosed and serviced first. Once all other conditions are serviced and only the 1st and 2nd gear whine are still present, refer to the following Service Procedure. Using the chart provided, select the parts that need to be replaced. NOTE IF PLANETARIES ARE LISTED, BOTH MUST BE REPLACED. SERVICE PROCEDURE Gear Whine Service Procedure 1. Determine whether the driveshaft only, planetaries only or both driveshaft and planetaries need to be replaced, refer to Application and Component replacement chart shown. 2. If just the driveshaft needs to be replaced follow the procedures as listed in the appropriate Workshop Manual section for driveshaft removal/replacement. 3. If the planetaries need to be replaced, using the appropriate model and year Workshop Manual, Section 307-01, Transmission Removal procedures, remove the transmission. 4. Discard the driveshaft ONLY if being replaced. Refer to application and component replacement chart. NOTE REPLACEMENT OF THE EXTENSION HOUSING SEAL AND BUSHING ARE NOT REQUIRED. DO NOT DISASSEMBLE BEYOND THE REVERSE PLANETARY. ALL SUBASSEMBLY STEPS ARE NOT REQUIRED FOR THIS PROCEDURE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Customer Interest for Drive/Propeller Shaft: > 02-22-2 > Nov > 02 > A/T - 5R55E 1st/2nd Gear Whining Noise > Page 5858 NOTE BOTH PLANETARIES MUST BE REPLACED OR THE REPAIR MAY NOT BE EFFECTIVE. 5. Using the Transmission Disassembly procedures remove the Forward Planetary Assembly (7A398) and the Reverse Planetary Assembly (7D006) and discard. Do not disassemble beyond the Reverse Planetary assembly. 6. Using the appropriate Transmission Assembly procedures, assemble the transmission and install BOTH NEW service Reverse Planetary Assembly (XL2Z-7D006-AA) and a new service Forward Planetary Assembly (XL2Z-7A398-AA). 7. Using the appropriate model and year Workshop Manual, Section 307-01, Transmission Installation procedures, install transmission. 8. If being replaced, Install the NEW service driveshaft 2L2Z-4602-AA as required for the appropriate application listed. 9. Verify repair. Clear DTCs. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 022202A Replace Transmission 5.5 Hrs. Forward And Reverse Planetary Assemblies (Includes Time To Remove And Install Transmission 5R55E) 2001-2003 Explorer Sport/Sport Trac And Ranger 4.0L 4X2 022202B Replace Transmission 7.0 Hrs. Forward And Reverse Planetary Assemblies (Includes Time To Remove And Install Transmission 5R55E) 2001-2003 Explorer Sport/Sport Trac And Ranger 4.0L 4X4 022202C Replace Driveshaft 0.4 Hr. Only 2002-2003 Explorer Sport Trac 4x2 DEALER CODING CONDITION BASIC PART NO. CODE 7A398 42 OASIS CODES: 501000 502000, 504000, 597997, 703200, 703400 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Customer Interest for Drive/Propeller Shaft: > 02-22-2 > Nov > 02 > A/T - 5R55E 1st/2nd Gear Whining Noise > Page 5859 DISCLAIMER Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: > 02-22-2 > Nov > 02 > A/T - 5R55E 1st/2nd Gear Whining Noise Drive/Propeller Shaft: All Technical Service Bulletins A/T - 5R55E 1st/2nd Gear Whining Noise Article No. 02-22-2 11/11/02 ^ NOISE - GEAR WHINE NOISE IN 1ST AND 2ND GEAR ONLY - VEHICLES EQUIPPED WITH 5R55E TRANSMISSION AND 4.0L ENGINE ONLY ^ TRANSMISSION - 5R55E - GEAR WHINE NOISE IN 1ST AND 2ND GEAR ONLY - VEHICLES EQUIPPED WITH 4.0L ENGINE ONLY FORD: 2001-2003 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER ISSUE Some 2001-2003 Rangers, 2001-2003 Explorer Sport/Sport Trac, built prior to 10/18/2002, equipped with a 5R55E automatic transmission and 4.0L engine, may exhibit a gear whine type of noise in 1st and 2nd gear ONLY. This may be caused by the Reverse and Forward Planetary assemblies and/or the driveshaft. ACTION Verify that only these conditions exist and no DTCs are present. If other conditions are present and DTCs exist they must be diagnosed and serviced first. Once all other conditions are serviced and only the 1st and 2nd gear whine are still present, refer to the following Service Procedure. Using the chart provided, select the parts that need to be replaced. NOTE IF PLANETARIES ARE LISTED, BOTH MUST BE REPLACED. SERVICE PROCEDURE Gear Whine Service Procedure 1. Determine whether the driveshaft only, planetaries only or both driveshaft and planetaries need to be replaced, refer to Application and Component replacement chart shown. 2. If just the driveshaft needs to be replaced follow the procedures as listed in the appropriate Workshop Manual section for driveshaft removal/replacement. 3. If the planetaries need to be replaced, using the appropriate model and year Workshop Manual, Section 307-01, Transmission Removal procedures, remove the transmission. 4. Discard the driveshaft ONLY if being replaced. Refer to application and component replacement chart. NOTE REPLACEMENT OF THE EXTENSION HOUSING SEAL AND BUSHING ARE NOT REQUIRED. DO NOT DISASSEMBLE BEYOND THE REVERSE PLANETARY. ALL SUBASSEMBLY STEPS ARE NOT REQUIRED FOR THIS PROCEDURE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: > 02-22-2 > Nov > 02 > A/T - 5R55E 1st/2nd Gear Whining Noise > Page 5865 NOTE BOTH PLANETARIES MUST BE REPLACED OR THE REPAIR MAY NOT BE EFFECTIVE. 5. Using the Transmission Disassembly procedures remove the Forward Planetary Assembly (7A398) and the Reverse Planetary Assembly (7D006) and discard. Do not disassemble beyond the Reverse Planetary assembly. 6. Using the appropriate Transmission Assembly procedures, assemble the transmission and install BOTH NEW service Reverse Planetary Assembly (XL2Z-7D006-AA) and a new service Forward Planetary Assembly (XL2Z-7A398-AA). 7. Using the appropriate model and year Workshop Manual, Section 307-01, Transmission Installation procedures, install transmission. 8. If being replaced, Install the NEW service driveshaft 2L2Z-4602-AA as required for the appropriate application listed. 9. Verify repair. Clear DTCs. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 022202A Replace Transmission 5.5 Hrs. Forward And Reverse Planetary Assemblies (Includes Time To Remove And Install Transmission 5R55E) 2001-2003 Explorer Sport/Sport Trac And Ranger 4.0L 4X2 022202B Replace Transmission 7.0 Hrs. Forward And Reverse Planetary Assemblies (Includes Time To Remove And Install Transmission 5R55E) 2001-2003 Explorer Sport/Sport Trac And Ranger 4.0L 4X4 022202C Replace Driveshaft 0.4 Hr. Only 2002-2003 Explorer Sport Trac 4x2 DEALER CODING CONDITION BASIC PART NO. CODE 7A398 42 OASIS CODES: 501000 502000, 504000, 597997, 703200, 703400 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: > 02-22-2 > Nov > 02 > A/T - 5R55E 1st/2nd Gear Whining Noise > Page 5866 DISCLAIMER Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Page 5867 Drive/Propeller Shaft: Specifications Driveshaft Torque Specifications Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Page 5868 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Page 5869 Drive/Propeller Shaft: Service and Repair Driveshaft-Rear Removal and Installation 1. With the vehicle in neutral, raise and support the vehicle. 2. Index-mark the driveshaft flange and the rear axle pinion flange. 3. Remove the four bolts. 4. CAUTION: The driveshaft flange fits tightly on the rear axle pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the driveshaft from the pinion flange. Pry only in the area shown, with a suitable tool, to disconnect the driveshaft flange from the pinion flange. Using a suitable tool as shown, disconnect the driveshaft flange from the rear axle pinion flange. 5. Index-mark the driveshaft and the extension housing. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Page 5870 6. NOTE: Do not rotate the driveshaft while removing. Lower the driveshaft and remove the slip yoke from the transmission output shaft. 7. Index-mark the transmission output shaft to the previously marked transmission extension housing. 8. CAUTION: If new bolts to retain the driveshaft to the axle are not available, coat the threads of the original bolts with Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specifications. CAUTION: The driveshaft flange fits tightly on the rear axle pinion flange pilot. To make sure that the driveshaft flange seats squarely on the pinion flange, tighten the bolts evenly in a cross pattern as shown. CAUTION: Make sure all index marks are aligned. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Service and Repair Slip Yoke: Service and Repair Driveshaft Slip Yoke Special Tools Special Tool(s) Disassembly 1. Remove the driveshaft. 2. CAUTION: Do not clamp the driveshaft in the jaws of a vise or similar holding fixture. Remove the driveshaft slip-yoke boot. 1 Index-mark the driveshaft and the driveshaft slip-yoke. 2 Cut and discard the driveshaft slip-yoke boot clamps. 3 Separate the driveshaft slip-yoke from the splined stub shaft, and remove the driveshaft slip-yoke boot. Inspect the driveshaft slip-yoke boot for damage and discard it if necessary. 3. Inspect the lubricant for contamination. If contaminated, inspect the stub shaft and driveshaft slip-yoke for wear. Discard the driveshaft if necessary. Assembly 1. Position the small driveshaft slip-yoke boot clamp on the splined stub shaft. 2. Position the end of the driveshaft slip-yoke boot with the smaller diameter opening on the splined stub shaft and slide the boot on the shaft as far as it will travel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Service and Repair > Page 5874 3. Using the special tool, crimp the small driveshaft slip-yoke boot clamp. 4. CAUTION: Align the index marks made during disassembly. Install the driveshaft slip-yoke. 1 Lubricate the stub shaft splines with approximately 10 grams (0.24 oz) of lubricant, and pull the driveshaft slip-yoke boot towards the driveshaft. Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M I C75-B. 2 Position the large driveshaft slip-yoke boot clamp. 3 Align the index marks made during disassembly, and install the driveshaft slip-yoke. 5. Set the driveshaft assembled length to specification. 1 Remove any excess grease from the driveshaft slip-yoke surfaces. 2 Position the driveshaft slip-yoke boot in the driveshaft slip-yoke boot groove. 3 Set the driveshaft assembled length to specification. Measure from the driveshaft weld to the end of the driveshaft slip-yoke. Set the assembled length to specification by moving the driveshaft slip-yoke inward or outward as necessary. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Service and Repair > Page 5875 4 Bleed air from the driveshaft slip-yoke boot. 6. Using the special tool, crimp the large driveshaft slip-yoke boot clamp. 7. Install the driveshaft. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Diagrams > Page 5879 Universal Joint: Description and Operation Universal Joints The universal joints are: lubed-for-life design and require no lubrication. - equipped with nylon thrust washers, located at each base of the bearing cup, which control end play, position the needle bearing and improve grease movement. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft Universal Joint-Slip Yoke Universal Joint: Service and Repair Driveshaft Universal Joint-Slip Yoke Driveshaft Universal Joint-Slip Yoke Special Tools Special Tool(s) Disassembly Initial disassembly 1. Remove the driveshaft. 2. CAUTION: Do not, under any circumstance, clamp the driveshaft assembly in the jaws of a vise or similar holding fixture. Denting or localizing fracture can result, causing driveshaft failure during vehicle operation. Place the driveshaft on a suitable workbench. Do not to damage the tube. 3. NOTE: If components are not marked and therefore installed incorrectly, driveline imbalance can occur. Index-mark the driveshaft components. 4. Remove all four of the snap rings. 5. Clamp the special tool in a vise. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft Universal Joint-Slip Yoke > Page 5882 Bearing cup removal 6. NOTE: If necessary, use a pair of pliers to remove a bearing cup that fails to press out all the way. Remove the driveshaft slip-yoke. 1 Position the driveshaft slip-yoke in the special tool. 2 Press out a bearing cup. 3 Rotate the driveshaft slip-yoke 180 degrees. 4 Press on the spider to remove the remaining bearing cup. 5 Remove the driveshaft slip-yoke. Final disassembly 7. Repeat Bearing cup removal to remove the remaining bearing cups and the spider from the driveshaft. 8. Clean the yoke area at each end of the driveshaft. Assembly Bearing cup installation 1. NOTE: Install the Universal Joint Kits as complete assemblies only. Do not mix components from other Kits. Install the bearing cup. 1 Start a new bearing cup into the driveshaft yoke. Check the needle bearings for correct positioning. 2 Position the new spider in the driveshaft yoke. 3 Using the special tool, press the bearing cup to just below the snap ring groove. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft Universal Joint-Slip Yoke > Page 5883 2. NOTE: Use the yellow snap rings supplied in the kit to assemble the universal joint (U-joint). If difficulty is encountered with the yellow snap rings, install the black snap rings. Remove the driveshaft from the special tool, and install the snap ring. Opposite bearing cup installation 3. Repeat Bearing cup installation to install the bearing cup and the snap ring on the opposite side of the driveshaft yoke. Slip-yoke installation 4. Inspect the driveshaft slip-yoke. Install a new yoke, if necessary. 5. Repeat Bearing cup installation to install the driveshaft slip-yoke and the remaining new bearing cups and snap rings. Final assembly 6. NOTE: Do not strike the bearings. Check the U-joints for freedom of movement. If binding, strike the yoke with a brass or plastic hammer. 7. Install the driveshaft. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft Universal Joint-Slip Yoke > Page 5884 Universal Joint: Service and Repair Driveshaft Universal Joint-Flange Yoke Driveshaft Universal Joint-Flange Yoke Special Tools Special Tool(s) Disassembly 1. Remove the driveshaft. 2. CAUTION: Do not clamp the driveshaft in a vise or similar holding fixture. Place the driveshaft on a suitable workbench, being careful not to damage the tube. 3. NOTE: If components are not marked and installed correctly, driveline imbalance can occur. Index-mark the positions of the driveshaft components. 4. Clamp the U-joint tool in a vise. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft Universal Joint-Slip Yoke > Page 5885 5. Remove all four of the snap rings. 6. Remove the driveshaft flange yoke. 1 Position the driveshaft flange yoke in the U-joint tool. 2 Press out a bearing cup. 3 Remove the driveshaft flange yoke. 4 Press on the spider to remove the remaining bearing cup. 5 Remove the driveshaft flange yoke. 7. Remove the spider. 1 Reposition the driveshaft in the U-joint tool. 2 Press out the bearing cup. 3 Rotate the driveshaft. 4 Press on the spider to remove the remaining bearing cup. 5 Remove the spider. 8. Clean the yoke area at the end of the driveshaft. Assembly Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft Universal Joint-Slip Yoke > Page 5886 1. NOTE: Universal joint kits are to be installed as complete assemblies only. Do not mix components from other U-joint kits. Install the spider. 1 Start a new bearing cup into the driveshaft yoke. Check the needle bearings for correct positioning. 2 Position the new spider in the driveshaft yoke. 3 Position the driveshaft in the U-joint tool. 4 Press the bearing cup to just below the snap ring groove. Repeat for the other bearing cup. 2. Inspect the driveshaft flange yoke. Install new, if necessary. 3. Install the driveshaft flange yoke. 1 Start a new bearing cup into the driveshaft flange yoke. Check the needle bearings for correct positioning. 2 Position the driveshaft flange yoke. 3 Position the driveshaft in the U-joint tool. 4 Press the bearing cup to just below the snap ring groove. Repeat for the other bearing cup. 4. NOTE: Use the yellow snap rings supplied in the kit to assemble the universal joint (U-joint). If difficulty is encountered with the yellow snap rings, install the black snap rings. Remove the driveshaft from the U-joint tool, and install the four snap rings. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft Universal Joint-Slip Yoke > Page 5887 5. NOTE: Do not strike the bearings. Check the U-joints for freedom of movement. If binding, strike the yoke with a brass or plastic hammer. 6. Install the driveshaft. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications Flex Plate Torque and Sequence NOTE: Special bolts are used for flexplate installation; do not use standard bolts. - Tighten the bolts in the sequence shown in two stages. - Stage 1: Tighten the bolts to 13 Nm (10 ft. lbs.). - Stage 2: Tighten the bolts to 71 Nm 452 ft. lbs.). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 5891 Flex Plate: Service and Repair Flexplate Removal 1. Remove the transmission. 2. Remove the flexplate. Installation 1. NOTE: Special bolts are used for flexplate installation; do not use standard bolts. Install the flywheel. Tighten the bolts in the sequence shown in two stages. - Stage 1: Tighten the bolts to 13 Nm (10 ft. lbs.). - Stage 2: Tighten the bolts to 71 Nm 452 ft. lbs.). 2. Install the transmission. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications Flywheel: Specifications Flywheel Torque and Tightening Sequence Flywheel Runout .................................................................................................................................. ................................................ 0.13 mm (0.005 inch) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Service and Repair > Removal and Installation Flywheel: Service and Repair Removal and Installation Flywheel Removal 1. Remove the disc and pressure plate. 2. Install the flywheel holding tool and remove the flywheel bolts. Remove the flywheel. Installation 1. Inspect the flywheel for cracks, hot spots and scoring. If damage is found to the flywheel friction surface, machine flywheel friction surface. If damage found to the ring gear teeth, replace ring gear. 2. NOTE: Apply threadlock and sealer to the flywheel bolt threads before installation. Position the flywheel onto the crankshaft and install the flywheel bolts. 3. Tighten the bolts in sequence to specification. 4. Install the disc and pressure plate. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Service and Repair > Removal and Installation > Page 5897 Flywheel: Service and Repair Dowels, Flywheel Dowels, Flywheel Removal and Installation 1. NOTE: Take care not to damage the flywheel dowel holes or the surface areas around the flywheel dowel during removal. Remove the flywheel dowels by using a drift pin where the flywheel dowel is installed in an open hole and a pair of locking pliers where the flywheel dowel is installed in a blind hole. 2. NOTE: Care should be taken to drive the flywheel dowel squarely into place until it is fully seated and to not damage the surrounding surface areas. Install all flywheel dowels by driving them into place using a brass or plastic mallet. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Service and Repair > Removal and Installation > Page 5898 Flywheel: Service and Repair Dowels, Flywheel Housing to Block Dowels, Flywheel Housing to Block Removal and Installation 1. NOTE: Take care not to damage the flywheel housing to block dowel holes or the surface areas around the flywheel housing to block dowel hole during removal. Remove the flywheel housing to block dowels using a drift pin where the flywheel housing to block dowel is installed in an open hole and a pair of locking pliers where the flywheel housing to block dowel is installed in a blind hole. 2. NOTE: Care should be taken to drive the flywheel housing to block dowel squarely into place until it is fully seated without damaging the surrounding surface areas. Install all flywheel housing to block dowels by driving them into place using a brass or plastic mallet. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component Information > Specifications Case: Specifications Case cover bolts .................................................................................................................................. ........................................... 16-22 Nm (12-16 ft. lbs.) Case plug ........................................................ ................................................................................................................................ 40-58 Nm (30-43 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Differential Fluid - M/T > Component Information > Specifications Differential Fluid - M/T: Specifications "Information not supplied by the manufacturer" Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Drain Plug, M/T > Component Information > Specifications Drain Plug: Specifications Drain plug ............................................................................................................................................ .......................................... 40-58 Nm (30-43 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Extension Housing, M/T > Component Information > Service and Repair Extension Housing: Service and Repair Extension Housing Removal 1. With the vehicle in NEUTRAL, raise and support the vehicle. 2. Remove the drain plug and drain the transmission fluid. 3. NOTE: To maintain initial driveshaft balance, index-mark the driveshaft to the rear axle pinion flange so it can be installed in its original position. Remove and support the rear driveshaft. 4. Remove the transfer case, if equipped. 5. Using the special tool, support the transmission. - Secure the transmission with a strap. 6. Remove the six crossmember bolts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Extension Housing, M/T > Component Information > Service and Repair > Page 5913 7. Remove the nuts, then remove the crossmember. 8. Remove the transmission mount. 1 Remove the bolts. 2 Reposition the exhaust mounting bracket. 9. Remove the extension housing. - 4x2 shown, 4x4 similar. Installation 1. Install the extension housing. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Extension Housing, M/T > Component Information > Service and Repair > Page 5914 2. Install the transmission mount. 1 Position the exhaust bracket. 2 Install the bolts. 3. Position the crossmember and install the six bolts and nuts. 4. Remove High-Lift Transmission Jack. 5. Install the nuts. 6. Install the transfer case, if equipped. 7. NOTE: To maintain initial driveshaft balance, align the index marks on the driveshaft and the rear axle pinion flange made during removal. Install the rear driveshaft. 8. Install the drain plug. 9. Refill the transmission with the specified amount of fluid. - Use MERCON Multipurpose Automatic Transmission Fluid XT-2-QDX or equivalent meeting Ford specification MERCON. 10. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fill Plug, M/T > Component Information > Specifications Fill Plug: Specifications Fill plug ................................................................................................................................................ .......................................... 40-58 Nm (30-43 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > M/T - Mercon(R) V ATF Usage Information Fluid - M/T: Technical Service Bulletins M/T - Mercon(R) V ATF Usage Information TSB 06-26-1 01/08/07 MERCON ATF IS BEING REPLACED BY MERCON V AS A SERVICE FLUID FOR SOME MANUAL TRANSMISSIONS FORD: 1981-2003 Escort 1984-1995 Thunderbird 1985-2007 Mustang 1985-1996 Bronco 1985-2007 Ranger 1986-1997 Aerostar 1991-2004 Explorer 1995-2007 F-150 1996-2007 F-Super Duty 2001-2003 Explorer Sport Trac, Explorer Sport LINCOLN: 2001-2002 Lincoln LS MERCURY: 1984-1995 Cougar 1987-1999 Tracer ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as the service fluid for manual transmissions originally requiring MERCON(R). ACTION Beginning immediately all manual transmission applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will continue until remaining inventory has been depleted. SERVICE PROCEDURE Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > M/T - Mercon(R) V ATF Usage Information > Page 5922 Service manual transmissions requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON/MERCON(R) V. For proper fluid application on current and past model manual transmissions refer to the fluid usage chart. (Figure 1) WARNING FULL SYNTHETIC MANUAL TRANSMISSION FLUID (XT-M5-QS), SAE 75W-90 API GL-4 GEAR OIL (XY-75W90-QGL) AND SAE 75W-90 PREMIUM SYNTHETIC TRANSAXLE LUBRICANT (XT-75W90-QGT) ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS RECOMMENDING THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > M/T - Mercon(R) V ATF Usage Information > Page 5923 Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Manual Transmission Capacity ............................................................................................................................................... ..................................................................... 5.1 Pints Note: Service refill capacity is determined by filling the transmission to the bottom of the filler hole with the vehicle on a level surface. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 5926 Fluid - M/T: Fluid Type Specifications Manual Transmission Fluid .................................................................................................................. ............................................................. Mercon ATF Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Flywheel Gear, M/T > Component Information > Service and Repair Flywheel Gear: Service and Repair Ring Gear Removal 1. WARNING: This procedure should be performed only by a properly equipped and experienced acetylene torch operator. To avoid personal injury, use tongs or wear welding gloves and safety goggles when handling the heated flywheel ring gear. Remove the transmission. 2. Remove the clutch pressure plate and clutch disc. 3. Remove the flywheel. 4. CAUTION: Do not heat the flywheel ring gear beyond 278°C (500°F). Use heat indicating crayons to prevent over heating. CAUTION: Tap the flywheel ring gear evenly to prevent binding. Remove the flywheel ring gear from the flywheel. Evenly heat the flywheel ring gear and use a brass drift to drive the flywheel ring gear off the flywheel. Installation WARNING: This procedure should be performed only by a properly equipped and experienced acetylene torch operator. To avoid personal injury, use tongs or wear welding gloves and safety goggles when handling the heated flywheel ring gear. 1. CAUTION: Do not heat the flywheel ring gear beyond 278°C (500°F). Use heat indicating crayons to prevent over heating. CAUTION: Keep the torch moving to prevent hot spots. Evenly heat the flywheel ring rear. 2. Install the flywheel ring gear. - The bevel on the flywheel ring gear must face the rear of the flywheel. - Use a brass drift. 3. Install the flywheel. 4. Install the clutch pressure plate and clutch disc. 5. Install the transmission. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Output Shaft, M/T > Component Information > Specifications Output Shaft: Specifications Output shaft locknut ............................................................................................................................. .................................. 216-274 Nm (160-202 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications Transmission Speed Sensor: Specifications Vehicle speed sensor bolt ......................................................................................................................................................... 11-13 Nm (98-115 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Specifications Shifter M/T: Specifications Gearshift lever bolt .............................................................................................................................. ........................................... 27-40 Nm (20-29 ft. lbs.) Gear selector interlock bolts ......................................................................................................................................................... 8-10 Nm (72-89 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Specifications > Page 5940 Shifter M/T: Service and Repair Shift Lever and Boot Removal and Installation 1. Raise the outer gearshift lever boot and console assembly to access the nut and eccentric stud that retains the upper gearshift lever to the lower gearshift lever. 1 Remove the two screws retaining the console to the floor. 2 Raise the outer gearshift lever boot and console assembly to access the nut and eccentric stud. 2. Remove the nut. 3. Install the nut on the LH side of the lever, then tighten the nut to remove the eccentric stud out of the gearshift lever. 4. Remove the upper gearshift lever and the outer gearshift lever boot and console assembly as an assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Specifications > Page 5941 5. CAUTION: Note the position of the vehicle identification tags on the top of the inner gearshift lever boot for correct installation. If necessary, remove the four screws and the inner gearshift lever boot. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Boot, M/T > Component Information > Specifications Shift Boot: Specifications Inner gearshift lever boot bolt ................................................................................................................................................... 10-14 Nm (89-123 inch lbs.) Outer gearshift lever boot screws ................................................................................................................................................. 5-94 Nm (45-79 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Boot, M/T > Component Information > Specifications > Page 5946 Shift Boot: Service and Repair "For information regarding this component please refer to shift lever service and repair" Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Specifications Transmission Mount: Specifications Transmission mount bolts ............................................................................................................................................................ 87-110 Nm (64-81 ft. lbs.) Transmission mount nuts .............................................................................................................................................................. 87-110 Nm (64-81 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Specifications Transmission Speed Sensor: Specifications Vehicle speed sensor bolt ......................................................................................................................................................... 11-13 Nm (98-115 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams Connector View C167 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams Connector View C279 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > PCM Inputs Transmission Mode Switch: Description and Operation PCM Inputs TRANSMISSION CONTROL SWITCH Transmission Control Switch (TCS) Transmission Control Switch (TCS) The Transmission Control Switch (TCS) (Figures 43 and 44) signals the PCM with key power whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > PCM Inputs > Page 5963 Transmission Mode Switch: Description and Operation PCM Output Transmission Control Indicator Lamp The Transmission Control Indicator Lamp (TCIL) is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Refer to Transmission Control Switch in Hardware PCM Inputs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > Page 5964 Transmission Mode Switch: Service and Repair Transmission Control Switch Removal and Installation 1. Remove the Transmission Control Switch (TCS). 1 Remove the cover. 2 Remove the TCS. 2. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission Range (TR) sensor screws .......................................................................................................................... 8-11 Nm (71-97 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5968 View 151-5 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5969 Connector View C167 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5970 Digital Transmission Range Sensor: Description and Operation Digital Transmission Range (TR) Sensor The digital Transmission Range (TR) sensor is located on the outside of the transmission at the manual lever. The digital TR sensor completes the start circuit in PARK, NEUTRAL, and the back-up lamp circuit in REVERSE. The digital TR sensor also opens and closes a set of four switches that are monitored by the Powertrain Control Module (PCM) to determine the position of the manual lever (P, R, N, (D), 3, 2, 1). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5971 Digital Transmission Range Sensor: Service and Repair Digital Transmission Range (TR) Sensor Special Tools Special Tool(s) Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Disconnect the shift cable from the manual control lever. 4. Disconnect the digital Transmission Range (TR) sensor electrical connector. 5. Remove the manual control outer lever nut and manual control outer lever. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5972 6. Remove the screws and the digital TR sensor. Installation 1. Install the digital TR sensor and loosely install the screws. 2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence. 3. Install the manual control outer lever and nut. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5973 4. Connect the digital Transmission Range (TR) sensor electrical connector. 5. Connect the shift cable to the manual control lever. 6. Verify that the shift cable is adjusted. 7. Lower the vehicle. 8. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Turbine shaft speed (TSS) sensor screw ....................................................................................................................................... 8-11 Nm (71-97 inch lbs.) Output shaft speed sensor (OSS) sensor screw ............................................................................................................................. 8-11 Nm (71-97 inch lbs.) Intermediate shaft speed sensor (ISS) sensor ................................................................................................................................ 8-11 Nm (71-97 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor View 151-5 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 5979 Transmission Speed Sensor: Locations Output Shaft Speed Sensor View 151-5 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 5980 View 151-6 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Intermediate Shaft Speed Sensor Connector View C164 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Intermediate Shaft Speed Sensor > Page 5983 Transmission Speed Sensor: Diagrams Output Shaft Speed Sensor Connector View C193 Connector View C1107 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5984 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED SENSOR The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Removal 1. Raise and support the vehicle. 2. Disconnect Output Shaft Speed (OSS) sensor electrical connector. 3. Remove OSS sensor. 1 Remove the OSS sensor screw. 2 Remove the OSS sensor from the transmission. - Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring. Installation 1. Inspect and lubricate O-ring with petroleum jelly. 1 Install the OSS sensor into the transmission. 2 Tighten OSS sensor screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor > Page 5987 2. Connect OSS sensor electrical connector. 3. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor > Page 5988 Transmission Speed Sensor: Service and Repair Intermediate Shaft Speed Sensor Intermediate Shaft Speed Sensor Removal 1. Raise and support the vehicle. 2. Disconnect Intermediate Shaft Speed (ISS) sensor electrical connector. 3. Remove ISS sensor. 1 Remove the ISS sensor screw. 2 Remove the ISS sensor from the transmission. - Inspect the ISS sensor O-ring for damage. If damaged, install a new O-ring. Installation 1. Inspect and lubricate O-ring with petroleum jelly. 1 Install the ISS sensor into the transmission. 2 Tighten ISS sensor screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor > Page 5989 2. Connect ISS sensor electrical connector. 3. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations The Transmission Fluid Temperature Sensor is located on the solenoid body. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Temperature Sensor/Switch: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. NOTE: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5995 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number or the component name in one of the the A-Z Component Lists, the Component Location description for that component can easily be found. See: Locations/Component Locations/A-Z Component List Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5996 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5997 the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5998 that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5999 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6000 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6001 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6002 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6003 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6004 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6005 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6006 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6007 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6008 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6009 Systems Overview Wire Color Code Identification Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6010 OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6011 Transmission Temperature Sensor/Switch: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6012 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6013 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6014 Transmission Temperature Sensor/Switch: Electrical Diagrams Diagram 29-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6015 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Page 6016 Transmission Temperature Sensor/Switch: Description and Operation Transmission Fluid Temperature (TFT) Sensor The transmission fluid temperature (TFT) sensor is a thermistor-type sensor that varies a reference voltage signal. The resistance in the TFT varies with temperature. The powertrain control module (PCM) monitors the voltage signal across the TFT, and uses this information to determine the transmission fluid temperature. The TFT is located on the main control body wiring harness assembly. The PCM uses the TFT signal to help determine shift scheduling, torque converter clutch operation and electronic pressure control (EPC). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications Transmission Speed Sensor: Specifications Vehicle speed sensor bolt ......................................................................................................................................................... 11-13 Nm (98-115 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations Pressure Regulating Solenoid: Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 6027 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 6028 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 6029 SSA, SSC solenoids 1. TCC solenoid 2. SSB, SSD solenoids 3. EPC solenoid Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Pressure Regulating Solenoid: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. NOTE: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6032 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number or the component name in one of the the A-Z Component Lists, the Component Location description for that component can easily be found. See: Locations/Component Locations/A-Z Component List Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6033 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6034 the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6035 that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6036 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6037 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6038 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6039 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6040 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6041 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6042 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6043 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6044 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6045 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6046 Systems Overview Wire Color Code Identification Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6047 OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6048 Pressure Regulating Solenoid: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6049 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6050 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6051 Pressure Regulating Solenoid: Exploded Views Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6052 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6053 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6054 Pressure Regulating Solenoid: Electrical Diagrams Diagram 29-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6055 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 6056 Pressure Regulating Solenoid: Description and Operation Electronic Pressure Control (EPC) Solenoid The electronic pressure control (EPC) solenoid is a variable force style (VFS) solenoid. The VFS type solenoid is an electro-hydraulic actuator combining a solenoid and a regulating valve. The powertrain control module (PCM) varies the current to the EPC solenoid. This action causes the solenoid to regulate transmission line pressure and line modulator pressure. This is done by producing resisting forces to the main regulator and line modulator circuits. These two circuits control clutch application pressures. The PCM has an adaptive learn strategy to electronically control the transmission which will automatically adjust the shift feel. When the battery has been disconnected or a new battery installed, certain transmission operating parameters may be lost. The PCM must relearn these parameters. During this learning process you may experience slightly firm shifts, delayed, or early shifts. This operation is considered normal and will not affect the function of the transmission. Normal operation will return once these parameters are stored by the PCM. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 6057 Pressure Regulating Solenoid: Service and Repair Solenoids-Shift, Torque Converter Clutch, Electronic Pressure Control Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal If equipped, loosen the nut and position the heat shield out of the way. 4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid. 6. Remove the transmission fluid filter. 1 Remove the transmission fluid filter screw. 2 Remove the transmission fluid filter. 7. NOTE: Main control assembly does not need to be removed for solenoid service. Remove wire loom guide and protector. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 6058 8. Disconnect the appropriate solenoid electrical connector. 1 Disconnect shift solenoids electrical connectors. 2 Disconnect the Torque Converter Clutch (TCC) solenoid electrical connector. 3 Disconnect the Electronic Pressure Control (EPC) solenoid electrical connector. 9. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve. CAUTION: Shift Solenoid (SSC) may pop out of its bore. This may damage the solenoid. Remove the shift solenoids. 1 Remove the wire harness 2 Remove the solenoid clamp screws. 3 Remove the solenoid clamp 4 Remove the appropriate solenoid(s) Installation 1. Install the new solenoid(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 6059 2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 2W plug. Install the solenoid clamp 1 Position the solenoid clamp on the main control valve body. 2 Install the solenoid clamp screws. 3. Connect the six solenoid electrical connectors. 1 Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2 Connect the Torque Converter Clutch (TCC) solenoid electrical connector. 3 Connect the Electrical Pressure Control (EPC) solenoid electrical connector. 4. CAUTION: Excessive pressure may break the retaining pins. Install the main control valve body wire loom. Align the retaining pins to the holes in the solenoid clamps and gently press in the main control valve body wire loom guide and protector. 5. Install the transmission fluid filter. 1 Install the transmission fluid filter. 2 Install the transmission fluid filter screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 6060 6. Install the transmission fluid pan. 1 Position a new transmission fluid pan gasket on the transmission fluid pan. 2 Align and install the transmission fluid pan. - Loosely install the transmission fluid pan screws. 7. Tighten the transmission fluid pan screws. - Tighten the transmission fluid pan screws in a crisscross sequence. 8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle. 10. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. 11. Fill the transmission to the correct fluid level and check for correct transmission operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications Shift Interlock Solenoid: Specifications Bolts retaining the shift lock actuator to the transmission column shift selector tube ............................................................................. 9 Nm (80 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 6064 Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator Removal and Installation 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches.Please refer to the appropriate location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable. Wait at least one minute before proceeding with the procedure to allow the backup power supply to deplete its energy. 2. Remove the lower steering column opening finish panel. 1 Remove the screws and position the hood release handle out of the way. 2 Remove the two screws from the lower steering column opening finish panel. 3 Pull outward to release the retaining clips and remove the lower steering column opening finish panel. 3. Remove the five bolts and the lower steering column opening finish panel reinforcement. 4. Remove the four nuts and lower the steering column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 6065 5. Remove the three bolts and separate the insert plate and shift lock actuator from the steering column. 6. Disconnect the electrical connector and remove the insert plate and shift lock actuator. 7. NOTE: The shift lock actuator clip is an assembly aid for the assembly plant. It is not necessary to install a new clip for installation. Remove and discard the clip. 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications Shift Solenoid: Specifications Solenoid clamp screws ........................................................................................................................ ............................................ 6-8 Nm (53-71 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 6069 Shift Solenoid: Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 6070 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 6071 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 6072 SSA, SSC solenoids 1. TCC solenoid 2. SSB, SSD solenoids 3. EPC solenoid Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. NOTE: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6075 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number or the component name in one of the the A-Z Component Lists, the Component Location description for that component can easily be found. See: Locations/Component Locations/A-Z Component List Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6076 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6077 the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6078 that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6079 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6080 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6081 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6082 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6083 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6084 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6085 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6086 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6087 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6088 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6089 Systems Overview Wire Color Code Identification Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6090 OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6091 Shift Solenoid: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6092 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6093 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6094 Shift Solenoid: Exploded Views Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6095 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6096 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6097 Shift Solenoid: Electrical Diagrams Diagram 29-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6098 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 6099 Shift Solenoid: Description and Operation Shift Solenoids A, B, C, and D Four On/Off shift solenoids allow the powertrain control module to control shift scheduling. - The solenoids are two-way, normally open style. - The shift solenoids (SSA, SSB, SSC, and SSD) provide gear selection by controlling the pressures of the shift valves. - SSD is also used to apply and release the coast clutch. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 6100 Shift Solenoid: Service and Repair Solenoids-Shift, Torque Converter Clutch, Electronic Pressure Control Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal If equipped, loosen the nut and position the heat shield out of the way. 4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid. 6. Remove the transmission fluid filter. 1 Remove the transmission fluid filter screw. 2 Remove the transmission fluid filter. 7. NOTE: Main control assembly does not need to be removed for solenoid service. Remove wire loom guide and protector. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 6101 8. Disconnect the appropriate solenoid electrical connector. 1 Disconnect shift solenoids electrical connectors. 2 Disconnect the Torque Converter Clutch (TCC) solenoid electrical connector. 3 Disconnect the Electronic Pressure Control (EPC) solenoid electrical connector. 9. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve. CAUTION: Shift Solenoid (SSC) may pop out of its bore. This may damage the solenoid. Remove the shift solenoids. 1 Remove the wire harness 2 Remove the solenoid clamp screws. 3 Remove the solenoid clamp 4 Remove the appropriate solenoid(s) Installation 1. Install the new solenoid(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 6102 2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 2W plug. Install the solenoid clamp 1 Position the solenoid clamp on the main control valve body. 2 Install the solenoid clamp screws. 3. Connect the six solenoid electrical connectors. 1 Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2 Connect the Torque Converter Clutch (TCC) solenoid electrical connector. 3 Connect the Electrical Pressure Control (EPC) solenoid electrical connector. 4. CAUTION: Excessive pressure may break the retaining pins. Install the main control valve body wire loom. Align the retaining pins to the holes in the solenoid clamps and gently press in the main control valve body wire loom guide and protector. 5. Install the transmission fluid filter. 1 Install the transmission fluid filter. 2 Install the transmission fluid filter screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 6103 6. Install the transmission fluid pan. 1 Position a new transmission fluid pan gasket on the transmission fluid pan. 2 Align and install the transmission fluid pan. - Loosely install the transmission fluid pan screws. 7. Tighten the transmission fluid pan screws. - Tighten the transmission fluid pan screws in a crisscross sequence. 8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle. 10. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. 11. Fill the transmission to the correct fluid level and check for correct transmission operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations Torque Converter Clutch Solenoid: Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 6107 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 6108 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 6109 SSA, SSC solenoids 1. TCC solenoid 2. SSB, SSD solenoids 3. EPC solenoid Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. NOTE: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6112 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number or the component name in one of the the A-Z Component Lists, the Component Location description for that component can easily be found. See: Locations/Component Locations/A-Z Component List Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6113 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6114 the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6115 that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6116 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6117 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6118 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6119 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6120 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6121 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6122 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6123 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6124 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6125 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6126 Systems Overview Wire Color Code Identification Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6127 OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6128 Torque Converter Clutch Solenoid: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6129 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6130 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6131 Torque Converter Clutch Solenoid: Exploded Views Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6132 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6133 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6134 Torque Converter Clutch Solenoid: Electrical Diagrams Diagram 29-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6135 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6136 Torque Converter Clutch Solenoid: Description and Operation Torque Converter Clutch (TCC) Solenoid The torque converter clutch (TCC) solenoid is used to control the apply and release of the TCC. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6137 Torque Converter Clutch Solenoid: Service and Repair Solenoids-Shift, Torque Converter Clutch, Electronic Pressure Control Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal If equipped, loosen the nut and position the heat shield out of the way. 4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid. 6. Remove the transmission fluid filter. 1 Remove the transmission fluid filter screw. 2 Remove the transmission fluid filter. 7. NOTE: Main control assembly does not need to be removed for solenoid service. Remove wire loom guide and protector. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6138 8. Disconnect the appropriate solenoid electrical connector. 1 Disconnect shift solenoids electrical connectors. 2 Disconnect the Torque Converter Clutch (TCC) solenoid electrical connector. 3 Disconnect the Electronic Pressure Control (EPC) solenoid electrical connector. 9. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve. CAUTION: Shift Solenoid (SSC) may pop out of its bore. This may damage the solenoid. Remove the shift solenoids. 1 Remove the wire harness 2 Remove the solenoid clamp screws. 3 Remove the solenoid clamp 4 Remove the appropriate solenoid(s) Installation 1. Install the new solenoid(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6139 2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 2W plug. Install the solenoid clamp 1 Position the solenoid clamp on the main control valve body. 2 Install the solenoid clamp screws. 3. Connect the six solenoid electrical connectors. 1 Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2 Connect the Torque Converter Clutch (TCC) solenoid electrical connector. 3 Connect the Electrical Pressure Control (EPC) solenoid electrical connector. 4. CAUTION: Excessive pressure may break the retaining pins. Install the main control valve body wire loom. Align the retaining pins to the holes in the solenoid clamps and gently press in the main control valve body wire loom guide and protector. 5. Install the transmission fluid filter. 1 Install the transmission fluid filter. 2 Install the transmission fluid filter screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6140 6. Install the transmission fluid pan. 1 Position a new transmission fluid pan gasket on the transmission fluid pan. 2 Align and install the transmission fluid pan. - Loosely install the transmission fluid pan screws. 7. Tighten the transmission fluid pan screws. - Tighten the transmission fluid pan screws in a crisscross sequence. 8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle. 10. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. 11. Fill the transmission to the correct fluid level and check for correct transmission operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams Connector View C167 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams Connector View C279 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > PCM Inputs Transmission Mode Switch: Description and Operation PCM Inputs TRANSMISSION CONTROL SWITCH Transmission Control Switch (TCS) Transmission Control Switch (TCS) The Transmission Control Switch (TCS) (Figures 43 and 44) signals the PCM with key power whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > PCM Inputs > Page 6151 Transmission Mode Switch: Description and Operation PCM Output Transmission Control Indicator Lamp The Transmission Control Indicator Lamp (TCIL) is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Refer to Transmission Control Switch in Hardware PCM Inputs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > Page 6152 Transmission Mode Switch: Service and Repair Transmission Control Switch Removal and Installation 1. Remove the Transmission Control Switch (TCS). 1 Remove the cover. 2 Remove the TCS. 2. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission Range (TR) sensor screws .......................................................................................................................... 8-11 Nm (71-97 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6156 View 151-5 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6157 Connector View C167 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6158 Digital Transmission Range Sensor: Description and Operation Digital Transmission Range (TR) Sensor The digital Transmission Range (TR) sensor is located on the outside of the transmission at the manual lever. The digital TR sensor completes the start circuit in PARK, NEUTRAL, and the back-up lamp circuit in REVERSE. The digital TR sensor also opens and closes a set of four switches that are monitored by the Powertrain Control Module (PCM) to determine the position of the manual lever (P, R, N, (D), 3, 2, 1). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6159 Digital Transmission Range Sensor: Service and Repair Digital Transmission Range (TR) Sensor Special Tools Special Tool(s) Removal 1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Disconnect the shift cable from the manual control lever. 4. Disconnect the digital Transmission Range (TR) sensor electrical connector. 5. Remove the manual control outer lever nut and manual control outer lever. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6160 6. Remove the screws and the digital TR sensor. Installation 1. Install the digital TR sensor and loosely install the screws. 2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. NOTE: The manual lever must be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence. 3. Install the manual control outer lever and nut. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6161 4. Connect the digital Transmission Range (TR) sensor electrical connector. 5. Connect the shift cable to the manual control lever. 6. Verify that the shift cable is adjusted. 7. Lower the vehicle. 8. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and this is a temporary condition and will eventually return to normal operating condition. Connect the battery ground cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Turbine shaft speed (TSS) sensor screw ....................................................................................................................................... 8-11 Nm (71-97 inch lbs.) Output shaft speed sensor (OSS) sensor screw ............................................................................................................................. 8-11 Nm (71-97 inch lbs.) Intermediate shaft speed sensor (ISS) sensor ................................................................................................................................ 8-11 Nm (71-97 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor View 151-5 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 6167 Transmission Speed Sensor: Locations Output Shaft Speed Sensor View 151-5 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Intermediate Shaft Speed Sensor > Page 6168 View 151-6 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Intermediate Shaft Speed Sensor Connector View C164 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Intermediate Shaft Speed Sensor > Page 6171 Transmission Speed Sensor: Diagrams Output Shaft Speed Sensor Connector View C193 Connector View C1107 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 6172 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED SENSOR The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Removal 1. Raise and support the vehicle. 2. Disconnect Output Shaft Speed (OSS) sensor electrical connector. 3. Remove OSS sensor. 1 Remove the OSS sensor screw. 2 Remove the OSS sensor from the transmission. - Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring. Installation 1. Inspect and lubricate O-ring with petroleum jelly. 1 Install the OSS sensor into the transmission. 2 Tighten OSS sensor screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor > Page 6175 2. Connect OSS sensor electrical connector. 3. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor > Page 6176 Transmission Speed Sensor: Service and Repair Intermediate Shaft Speed Sensor Intermediate Shaft Speed Sensor Removal 1. Raise and support the vehicle. 2. Disconnect Intermediate Shaft Speed (ISS) sensor electrical connector. 3. Remove ISS sensor. 1 Remove the ISS sensor screw. 2 Remove the ISS sensor from the transmission. - Inspect the ISS sensor O-ring for damage. If damaged, install a new O-ring. Installation 1. Inspect and lubricate O-ring with petroleum jelly. 1 Install the ISS sensor into the transmission. 2 Tighten ISS sensor screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Output Shaft Speed (OSS) Sensor > Page 6177 2. Connect ISS sensor electrical connector. 3. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations The Transmission Fluid Temperature Sensor is located on the solenoid body. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Temperature Sensor/Switch: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. NOTE: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6183 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number or the component name in one of the the A-Z Component Lists, the Component Location description for that component can easily be found. See: Locations/Component Locations/A-Z Component List Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6184 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6185 the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6186 that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6187 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6188 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6189 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6190 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6191 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6192 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6193 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6194 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6195 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6196 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6197 Systems Overview Wire Color Code Identification Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6198 OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6199 Transmission Temperature Sensor/Switch: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6200 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6201 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6202 Transmission Temperature Sensor/Switch: Electrical Diagrams Diagram 29-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6203 Diagram 29-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Page 6204 Transmission Temperature Sensor/Switch: Description and Operation Transmission Fluid Temperature (TFT) Sensor The transmission fluid temperature (TFT) sensor is a thermistor-type sensor that varies a reference voltage signal. The resistance in the TFT varies with temperature. The powertrain control module (PCM) monitors the voltage signal across the TFT, and uses this information to determine the transmission fluid temperature. The TFT is located on the main control body wiring harness assembly. The PCM uses the TFT signal to help determine shift scheduling, torque converter clutch operation and electronic pressure control (EPC). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications Transmission Speed Sensor: Specifications Vehicle speed sensor bolt ......................................................................................................................................................... 11-13 Nm (98-115 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Locations View 151-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Differential Speed Sensor > Component Information > Locations View 151-16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Differential Speed Sensor > Component Information > Locations > Page 6217 Connector View C455 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications Electronic Brake Control Module: Specifications Control module bolts ............................................................................................................................ ................................................ 1.5 Nm (13 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications > Page 6221 View 151-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications > Page 6222 Connector View C135 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications > Page 6223 Electronic Brake Control Module: Service and Repair Module-Anti-Lock Brake Control Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the electrical connectors. 3. Remove the anti-lock brake control module. 1 Remove the bolts. 2 Remove the anti-lock brake control module. 4. CAUTION: Once the new module is installed, the module configuration information may have to be entered. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications > Page 6224 To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications Brake pressure switch ......................................................................................................................... ................................................... 17.5 Nm (13 ft. lbs.) Brake pressure control valve .......................... ....................................................................................................................................... 17.5 Nm (13 ft. lbs.) Hydraulic control unit (HCU) to bracket bolts ........................................................................................................................................ 8 Nm (71 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 6228 Hydraulic Control Assembly - Antilock Brakes: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Antilock Brakes / Traction Control Systems; Testing and Inspection. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 6229 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Hydraulic Control Unit Removal and Installation WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. Disconnect the battery ground cable. 2. Disconnect the electrical connector by lifting up on the release tab. 3. Disconnect the brake lines from the Hydraulic Control Unit (HCU). 4. Remove the HCU. 1 Remove the bolts. 2 Remove the HCU. 5. If necessary, remove the anti-lock brake control module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 6230 6. CAUTION: After the electronic hydraulic control unit is installed, it is necessary to bleed the hydraulic brake system. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. ^ Bleed the HCU. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications Front anti-lock brake sensor bolt ........................................................................................................................................................... (12 Nm) (8.5 ft. lbs.) Rear anti-lock brake sensor bolt ............................................................................................................................................................. (27 Nm) (20 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Left front View 151-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Left front > Page 6236 View 151-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Left Front Connector View C150 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 6239 Connector View C160 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front Wheel Speed Sensor: Service and Repair Sensor, Front Sensor-Front Removal and Installation 1. Raise and support the vehicle. 2. Disconnect the front anti-lock brake sensor wire from the vehicle frame. 1 Disconnect the electrical connector. 2 Unclip the front anti-lock brake sensor wire from the vehicle frame. 3. Remove the front anti-lock brake sensor. 1 Remove the bolt. 2 Remove the front anti-lock brake sensor. 4. NOTE: Plug the sensor mount opening and thoroughly clean the mounting surface. Apply High-Temperature 4x4 Front Axle and Wheel Bearing Grease E8TZ-19590-A meeting Ford Specification ESA-MIC198-A. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front > Page 6242 Wheel Speed Sensor: Service and Repair Sensor, Rear Sensor-Rear Removal and Installation 1. Raise and support vehicle. NOTE: Clean off dirt and foreign material that may have collected around the rear anti-lock brake sensor before removal. 2. Remove the rear anti-lock brake sensor. 1 Disconnect the rear anti-lock brake sensor electrical connector. 2 Remove the bolt. 3 Remove the rear anti-lock brake sensor. 3. NOTE: Thoroughly clean the mounting surface. NOTE: Inspect the anti-lock brake sensor O-ring for damage; lightly lubricate the O-ring with SAE 75W-140 High Performance Rear Axle Lubricant FITZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding Brake Bleeding: Service and Repair Brake Caliper Bleeding Caliper WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water to induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. 1. NOTE: It is not necessary to do a complete brake system bleed if only the disc brake caliper was disconnected. Place a box end wrench on the disc brake caliper bleeder screw. Attach a rubber drain tube to the disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3. Loosen the disc brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 4. Tighten the disc brake caliper bleeder screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6247 Brake Bleeding: Service and Repair Brake System Manual Bleeding Manual WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. NOTE: When any part of the hydraulic system has been disconnected for repair or installation of new components, air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 2. NOTE: Disc brake is shown, drum brake is similar. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 3. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6248 4. NOTE: Disc brake is shown, drum brake is similar. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH rear bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 5. Continue bleeding the system going in order from the LH rear bleeder screw to the RH front bleeder screw ending with the LH front bleeder screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6249 Brake Bleeding: Service and Repair Brake System Pressure Bleeding Pressure WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water to induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 2. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers of pressure bleeding equipment. Follow the instructions of the manufacturer when installing the adapter. Install the bleeder adapter to the brake master cylinder reservoir, and attach the bleeder tank hose to the fitting on the adapter. 3. NOTE: Disc brake is shown, drum brake is similar. NOTE: Bleed the longest line first. Make sure the bleeder tank contains enough specified brake fluid to complete the bleeding operation. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 4. Open the valve on the bleeder tank. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6250 5. NOTE: Disc brake is shown, drum brake is similar. Loosen the RH rear bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten the RH rear bleeder screw and remove the rubber hose. 6. Continue bleeding the rear of the system, going in order from the LH rear bleeder screw to the RH front bleeder screw, ending with the LH front bleeder screw. 7. Close the bleeder tank valve. Remove the tank hose from the adapter, and remove the adapter. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6251 Brake Bleeding: Service and Repair Four Wheel ABS Hydraulic Control Unit (HCU) Four Wheel Anti-Lock Brake System (4WABS) Hydraulic Control Unit (HCU) WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water to induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. NOTE: This procedure only needs to be carried out if a new 4-Wheel Anti-Lock Brake (4WABS) Hydraulic Control Unit (HCU) has been installed. 1. Connect the scan tool DCL cable adapter into the vehicle Data Link Connector (DLC) under the dash, and follow the scan tool instructions for bleeding. 2. Clean all dirt from and remove the brake master cylinder filler cap, and fill the brake master cylinder reservoir with the specified brake fluid. 3. NOTE: Disc brake is shown, drum brake is similar. Connect a clear drain tube to the RH rear bleeder screw and the other end in a container partially filled with recommended brake fluid. 4. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6252 5. NOTE: Disc brake is shown, drum brake is similar. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 6. Continue bleeding the system, going in order from the LH rear bleeder screw to the RH front bleeder screw, ending with the LH front bleeder screw. 7. Repeat the bleed procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6253 Brake Bleeding: Service and Repair Master Cylinder Priming - In-Vehicle or Bench Master Cylinder Priming-In-Vehicle or Bench Special Tool(s) WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake component and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or installation, air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. NOTE: When a new brake master cylinder has been installed or the system has been emptied or partially emptied, it must be primed to prevent air from entering the system. 1. For in-vehicle priming, disconnect the brake lines from the brake master cylinder. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6254 2. For bench priming, mount the brake master cylinder in a vise. 3. Install short brake tubes with the ends bent into the brake master cylinder reservoir. ^ Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A. 4. For a new brake master cylinder, loosen the brake pressure switch. 5. Slowly depress and hold the primary piston or, for in-vehicle driving, have an assistant slowly depress and hold the brake pedal. Tighten the brake pressure switch. 6. Repeat the above three steps until no air bubbles are visible in the expelled fluid. 7. Slowly depress the primary piston or, for in-vehicle priming, have an assistant slowly pump the brake pedal until clear brake fluid flows from both brake tubes with no air bubbles. 8. If necessary, install the brake master cylinder into the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6255 9. Remove the short brake tubes and install the master cylinder outlet tubes. 10. Loosen a brake outlet tube at the 4WABS Hydraulic Control Unit (HCU). 11. NOTE: Refill the brake master cylinder reservoir as necessary. Have an assistant depress and hold the brake pedal. Tighten the outlet tube fitting at the HCU. 12. Repeat the above three steps until no air bubbles are visible in the expelled brake fluid. 13. Repeat the above four steps for the remaining master cylinder outlet tube. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6256 14. Connect one end of a flexible tube to the master cylinder bleeder screw. Submerge the other end in a container partially filled with the specified brake fluid. 15. Have an assistant pump and then hold firm pressure on the brake pedal. 16. NOTE: Refill the brake master cylinder reservoir as necessary. Loosen the master cylinder bleeder screw until brake fluid flows out of the drain tube. 17. Tighten the master cylinder bleeder screw. 18. Repeat the above three steps until there are no air bubbles in the expelled brake fluid. 19. Bleed the brake system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications Brake Pedal Assy: Specifications Brake pedal bracket bolts and nuts ........................................................................................................................................................... 25 Nm (18 ft. lbs.) Brake pedal bracket nuts ....................................................................................... .................................................................................... 25 Nm (18 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 6260 Brake Pedal Assy: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Brakes and Traction Control; Testing and Inspection. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 6261 Brake Pedal Assy: Service and Repair Brake Pedal And Bracket Removal and Installation All vehicles 1. NOTE: When removing the stoplight switch, retain the bushing and hairpin clip. They will be required for installation. Disconnect the brake booster push rod. 1 Remove the hairpin clip. 2 Separate the stoplight switch and the brake booster push rod from the brake pedal pin. 3 Remove the brake booster push rod bushing. Vehicles with manual transmission 2. Disconnect the clutch master cylinder push rod. 3. Disconnect the Clutch Pedal Position Switch (CPP). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 6262 4. Remove the clutch master cylinder by rotating the clutch master cylinder 45 degrees clockwise. 5. Remove the bulkhead sound insulator. All vehicles 6. Remove the bolts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 6263 7. CAUTION: Support the brake master cylinder and power brake booster in the engine compartment. Remove the nuts and the brake pedal assembly. 8. To install reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Front Caliper bleeder screw, rear ................................................................................................................. .................................................. 20 Nm (15 ft. lbs.) Caliper bleeder screw, front ................................ .................................................................................................................................. 20 Nm (15 ft. lbs.) Front disc brake caliper anchor plate bolts ............................................................................................................................... 98-132 Nm (72-97 ft. lbs.) Disc brake caliper bolts .............................................................................................................................................................. 28-36 Nm (21-26 ft. lbs.) Rear Brake caliper bolts ............................................................................................................................... ................................................. 27 Nm (20 ft. lbs.) Caliper flow bolt ................................................... ..................................................................................................................... 30-40 Nm (23-29 ft. lbs.) Rear wheel disc brake adapter bolts ................................................................................................................................................... 108 Nm (80 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front Brake Caliper: Service and Repair Front Caliper Removal and Installation Caliper Removal 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. WARNING: Use of any other than approved DOT 3 brake fluid will cause damage to brake components and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: Do not clamp the brake hose. The hose can be damaged. Disconnect the front brake hose. 1 Remove the front brake hose bolt. 2 Disconnect the front brake hose. 3 Remove and discard the copper washers Plug the front brake hose. 4. Remove the disc brake caliper. 1 Remove the disc brake caliper bolts. 2 Lift the disc brake caliper off the front disc brake caliper anchor plate Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6270 5. Inspect the disc brake caliper for leaks. ^ If leaks are found, disassembly is required. Installation 1. Install the disc brake caliper. 1 Install the disc brake caliper. 2 Install the disc brake caliper bolts. 2. Install the front brake hose. ^ Use new copper washers; connect the front brake hose. ^ Install the front brake hose bolt. 3. Bleed the disc brake caliper. 4. Install the wheel and tire assembly. 5. Check the brake system for correct operation. Caliper Disassembly and Assembly Caliper Disassembly WARNING: Use of any brake fluid other than approved DOT 3 will cause permanent damage to brake components and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water to induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6271 water. NOTE: Use clean, fresh Ford High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or equivalent meeting Ford specification ESA-M6C25A ^ Do not reuse brake fluid drained or bled from the system. ^ Do not use brake fluid that has been stored in an open container. ^ Do not use contaminated brake fluid 1. Remove the disc brake caliper. 2. Drain remaining brake fluid from the disc brake caliper 3. Secure the disc brake caliper in a vise. 4. Remove the caliper pistons. 1 Place a block of wood between the caliper bridge and the caliper pistons. 2 Apply low air pressure to the fluid port in the disc brake caliper. 3 Force out the caliper piston to the block of wood. 4 Remove the block of wood and the caliper pistons. 5. Remove and discard the piston seals and boots. 6. NOTE: Do not hone the caliper bores. Pistons are not available for honed caliper bores. If the caliper bores are excessively scored or corroded, install a new disc brake caliper. Assembly 1. CAUTION: Never reuse piston seals or dust boots. NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been allowed to stand in an open container for an Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6272 extended period of time. Lubricate the piston boot, caliper piston, piston seal, and cylinder bores with High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A. 2. Install the caliper pistons. 1 Install the piston seal. 2 Install the piston boot. 3 CAUTION: Be careful not to damage or dislodge the piston seal. Insert the caliper piston. 4 Press the caliper piston into the caliper bore, being careful not to cock the caliper piston. 3. Install the disc brake caliper. Brake Caliper Anchor Plate Brake Caliper Anchor Plate Removal 1. NOTE: 4x4 is shown, 4x2 is similar. Remove the pads. 2. Remove the front disc brake caliper anchor plate. 1 Remove the two front disc brake caliper anchor plate bolts. 2 Remove the front disc brake caliper anchor plate. Installation 1. NOTE: Use new brake caliper anchor plate bolts when installing the brake caliper anchor plate. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6273 Install the front disc brake caliper anchor plate. 1 Position the front disc brake caliper anchor plate. 2 Install new front disc brake caliper anchor plate bolts. 2. Install the pads. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6274 Brake Caliper: Service and Repair Rear Caliper Removal and Installation Caliper Removal 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: Do not clamp the brake hose. The hose can be damaged. Disconnect the brake hose. 1 Remove the bolt. 2 Disconnect the rear wheel brake hose. 3 Remove the copper washers and plug the brake hose. 4. CAUTION: Do not remove the guide pins or guide pin boots unless a problem is suspected. The guide pins are meant to be sealed for life and are not repairable. Use Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A (Motorcraft WA-10) or an equivalent silicone compound meeting Ford specification ESE-MlC171-A for re-lubing the caliper slide pins. Other greases can swell the guide pin boots, resulting in contamination and accelerated corrosion or wear of the caliper slide pin mechanism. Remove the rear disc brake caliper. 1 Remove the brake caliper bolts. 2 Lift the rear disc brake caliper off the rear disc brake caliper anchor plate. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6275 5. Inspect the rear disc brake caliper for leaks. ^ If leaks are found, disassembly is required. Installation 1. CAUTION: To prevent interference with rear disc brake caliper operation, install only the correct caliper bolt. NOTE: Make sure the stainless steel shoe slippers are correctly positioned. Install new slippers if worn or damaged. NOTE: When installed, the locator notch on the brake pads will be located at the upper end of the rear disc brake caliper. Install the rear disc brake caliper. 2. Install the rear wheel brake hose. ^ Connect the brake hose and install the caliper flow bolt. ^ Use new copper washers. 3. Bleed the disc brake caliper. 4. Install the wheel and tire assembly. 5. Verify correct brake operation. Caliper Disassembly and Assembly Caliper Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6276 Special Tool(s) Disassembly WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water to induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. Remove the rear disc brake caliper. 2. Drain the remaining brake fluid from the rear disc brake caliper. 3. Secure the rear disc brake caliper in a vise. 4. Remove the rear disc brake piston. ^ Place a block of wood between the caliper bridge and the rear disc brake piston. ^ Apply low air pressure to the fluid port in the rear disc brake caliper. ^ Force the rear disc brake piston out to the block of wood. ^ Remove the block of wood and the rear disc brake piston. 5. NOTE: Do not hone the cylinder bore. Pistons are not available for honed cylinder bores. If the rear disc brake caliper cylinder bore/piston is excessively scored or corroded, install a new rear disc brake caliper. Remove and discard the piston seal and dust boot. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6277 Assembly CAUTION: Never reuse the piston seal or dust boot. NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been allowed to stand in an open container for an extended period of time. 1. Lubricate the following with High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. ^ cylinder bore ^ piston seal ^ rear disc brake piston ^ dust boot 2. Install the piston seal. 3. Install the dust boot. 4. CAUTION: Be careful not to damage or dislodge the piston seal. Install the rear disc brake piston. 5. Install the rear disc brake caliper. Rear Disc Brake Adapter Adapter Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6278 Removal and Installation 1. Disconnect the rear parking brake cable guide. 2. Remove the axle shaft. 3. Remove the bolts and the rear wheel disc brake adapter. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications Brake Pad: Specifications Front Disc brake lining wear limit .................................................................................................................. ............................................... 2.5 mm (0.10 inch) Rear Disc brake lining wear limit .................................................................................................................. ............................................. 1.0 mm (0.039 inch) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front Brake Pad: Service and Repair Front Pads Removal 1. Remove brake fluid in the master cylinder reservoir until the reservoir is half full. 2. Raise and support the vehicle. 3. Remove the wheel and tire assembly. 4. CAUTION: Install a new pad if worn to or past the specified thickness above the metal backing plate. Install new pads in complete axle sets. Inspect the pads for wear or contamination. 5. Remove the lower caliper bolt on the RH caliper and the upper caliper bolt on the LH caliper first. 6. Rotate the disc brake caliper away from the brake disc rotor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6284 7. Remove the pads and the slippers. 1 Remove the pads. 2 Remove the stainless slippers. 8. Inspect the brake disc. ^ If the brake disc is cracked, install a new brake disc. ^ If diagnosis has revealed vibration in the steering wheel, seat, or brake pedal while braking, machine the brake disc. Heavily scored brake discs, similar to that caused by linings worn to the backing plate, must also be machined. ^ Measure the brake disc for minimum thickness. ^ If the brake disc is not within specification, install a new brake disc. 9. Inspect the disc brake caliper for leaks. ^ If leaks are found, disassembly is required. Installation Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6285 1. NOTE: Use a suitable suction device to remove brake fluid from the master cylinder. NOTE: Clean the support bracket and slipper surfaces. Install the slippers and the pads. 1 Install the slippers. 2 Install the pads. 2. NOTE: If installing new pads, the caliper pistons must be compressed using a C-clamp and a wooden block. Lower the brake fluid level in the master cylinder if required. Rotate the disc brake caliper into the anchor bracket. 3. Install the caliper bolt. 4. Install the wheel and tire assembly. 5. Check the brake system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6286 Brake Pad: Service and Repair Rear Pads Removal 1. Remove brake fluid in the master cylinder reservoir until the reservoir is half full. 2. CAUTION: Install new pads if worn to or past the specified thickness above the metal backing plate or rivets. Install new pads in complete axle sets. Inspect the brake pads for wear or contamination. Install new pads if worn to or past specification. 3. NOTE: It is not necessary to remove the rear wheel brake hose when carrying out this procedure. Remove the rear disc brake caliper. 4. CAUTION: Do not allow grease, oil, brake fluid or other contaminants to contact the brake pads. Remove the brake pads. 5. Retract the caliper piston into the rear disc brake caliper. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6287 6. Remove and discard the slippers. 7. Inspect the brake disc. ^ If the brake disc is cracked, install a new brake disc. ^ If diagnosis has revealed vibration in the steering wheel, seat, or brake pedal while braking, machine the brake disc. Heavily scored brake discs, similar to that caused by linings worn to the backing plate, must also be machined. ^ Measure the brake disc for minimum thickness. ^ If the brake disc is not within specification, install a new brake disc. Installation 1. CAUTION: New stainless steel slippers must be installed when new brake pads are installed, even if the slippers appear undamaged. Make sure the slippers are correctly positioned with the slipper ends snug against the outboard end of the anchor plate rail. Clean the slipper mating surface, and install the new slippers. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6288 2. CAUTION: Install new brake pads in full axle sets. Do not install new brake pads on only one side of the vehicle. Install the brake pads. 3. Install the rear disc brake caliper. 4. Verify correct brake operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications Brake Rotor/Disc: Specifications .............................................................................................................................................................. ........................................................ Min Thickness Front .................................................................................................................................................... ............................................. 0.9646 inch (24.50mm) Rear ..................................................................................................................................................... .................................................. 0.4331 inch (11mm) Sport/Sport Trac Rear From 08/19/02 ............................................................................................................................................. 0.4134 inch (10.50mm) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front Brake Rotor/Disc: Service and Repair Front Brake Disc Disc Removal All vehicles 1. Remove the front disc brake caliper anchor plate. 4x4 vehicles 2. NOTE: Match-mark the brake disc and hub. Remove the brake disc. 3. CAUTION: Use a hub-mount brake lathe if necessary to machine the brake disc. Measure the brake disc and resurface as necessary. Install a new brake disc if beyond specification. 4x2 vehicles 4. NOTE: Match-mark the brake disc and hub. Remove the brake disc and hub as follows: 1 Remove the hub grease cap. 2 Remove the cotter pin. 3 Remove the nut retainer. 4 Remove the spindle nut. 5 Remove the front wheel outer bearing retainer washer. 6 Remove the outer front wheel bearing. 7 Remove the brake disc and hub. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front > Page 6294 5. Remove the wheel hub grease seal and wheel bearing. 1 Remove the wheel hub grease seal. 2 Remove the wheel bearing. 6. CAUTION: Use a hub-mount brake lathe if necessary to machine the brake disc. Measure the brake disc, and resurface as necessary. Install a new brake disc if beyond specification. Installation 4x4 vehicles 1. Position the brake disc to the wheel hub. ^ Use Metal Brake Parts Cleaner F6AZ-2C410-AB or equivalent to clean the brake disc. ^ Using match-marks, mount the brake disc on the hub. ^ Apply High Temperature Nickel Anti-Seize Lubricant F6AZ-9L494-AA or equivalent meeting Ford specification ESE-M12A4-A to the hub mounting surface to prevent future corrosion. 4x2 vehicles 2. Thoroughly clean and inspect the front wheel bearings and the brake disc and hub. ^ Use Metal Brake Parts Cleaner F6AZ-2C410-AB or equivalent. 3. Lubricate the front wheel bearings. ^ Use Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front > Page 6295 4. Install a new wheel hub grease seal. 1 Install the inner front wheel bearing. 2 Install a new wheel hub grease seal. 5. Install the brake disc and hub. 1 Position the brake disc and hub. 2 Install the outer front wheel bearing. 3 Install the front wheel outer bearing retainer washer. 4 Install the spindle nut. 6. Tighten the spindle nut while rotating the brake disc and hub. 7. Loosen the spindle nut. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front > Page 6296 8. Tighten the spindle nut while rotating the brake disc and hub. 9. Install the following components: 1 Install the nut retainer. 2 Install the cotter pin. 3 Install the hub grease cap. All vehicles 10. Install the front disc brake caliper anchor plate. Brake Disc Shield Shield Removal and Installation 1. Remove the brake disc. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front > Page 6297 2. Remove the bolts and the brake disc shield. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front > Page 6298 Brake Rotor/Disc: Service and Repair Rear Brake Disc DISC Removal and Installation 1. NOTE: When removing the rear brake disc in this procedure it is not necessary to disconnect the hydraulic lines. Remove the rear disc brake caliper. 2. NOTE: If the rear brake disc binds on the rear parking brake shoe and linings, remove the adjustment hole access plug and retract the parking brake shoe and lining. Remove the rear brake disc. 3. CAUTION: Use a hub-mount brake lathe if necessary to machine the rear brake disc. Measure the rear brake disc, and resurface as necessary. Install a new rear brake disc if beyond specification. 4. To install, reverse the removal procedure. Brake Disc Shield Shield Removal 1. Remove the rear wheel disc brake adapter. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front > Page 6299 2. Remove the rear wheel disc brake shield. 1 Drill out the rivet, (if present). 2 Remove the rear wheel disc brake shield. Installation 1. NOTE: Because the rear wheel disc brake shield is held in position by the four rear wheel disc brake adapter bolts, a new rivet is not required. Seal the rivet hole with Clear Silicone Rubber F7AZ-19554-CA or equivalent meeting Ford specification ESB-M4G92-A, and install the rear wheel disc brake shield. 2. Install the rear wheel disc brake adapter. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications Backing Plate: Specifications Brake backing plate nuts .......................................................................................................................................................... 54.5-68.1 Nm (40-50 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications > Page 6304 Backing Plate: Service and Repair Backing Plate Removal and Installation 1. Remove the rear brake shoes and linings. 2. Pull back the parking brake cable spring and disconnect the parking brake lever. 3. Remove the axle shaft or the axle shaft and rear hub, if so equipped. 4. Compress the cable retainer and pull the parking brake rear cable and conduit from the brake backing plate. 5. Remove the rear wheel cylinder. 1 Disconnect the brake line fitting. 2 Remove the two rear wheel cylinder bolts and remove the rear wheel cylinder. 6. Remove the four backing plate-to-axle flange nuts and bolts and the brake backing plate. 7. To install, reverse the removal procedure. 8. Bleed the brake system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications Brake Drum: Specifications .............................................................................................................................................................. .............................................. Max Drum Diameter Rear ..................................................................................................................................................... ......................................... 11.0866 inch (281.60mm) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Page 6308 Brake Drum: Service and Repair Drum Special Tools Special Tool(s) Removal and Installation WARNING: Asbestos fiber dust can be present on brake and clutch assemblies and is hazardous to health if inhaled. Brake and clutch assemblies must be cleaned using a vacuum cleaner recommended for use with asbestos fibers, such as a Brake/Clutch/Service Vacuum. The bag must be labeled per OSHA instructions, sealed, and the trash hauler notified as to the bag's contents. WARNING: If a vacuum suitable for asbestos is not available, cleaning must be done wet. If dust generation is still possible, technicians must wear government-approved toxic dust purifying respirators. The Occupational Safety And Health Act (OSHA) requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians performing brake or clutch repair are to be present in the area. WARNING: To reduce the possibility of uneven braking, always install new rear brake shoes and linings at both ends of an axle. NOTE: Make sure that the parking brake control is fully released. 1. Remove the wheel and tire assembly. 2. CAUTION: Use of a brake drum puller or a torch is not recommended. Brake drum distortion can result. NOTE: If the brake drum is rusted to the axle shaft pilot diameter, tap the center of the brake drum between the wheel studs. Remove the brake drum. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Page 6309 1 Remove and discard the spring nut. 2 Pull the brake drum off the axle shaft. 3. NOTE: If the brake drum will not come off, follow these steps. Loosen the brake shoe adjusting screw nut. 1 Using a screwdriver, move the brake shoe adjusting lever off the brake adjuster screw. 2 NOTE: Move the adjustment tool handle downward to loosen the brake shoe adjusting screw nut. Use the Brake Adjustment Tool to loosen the brake shoe adjusting screw nut. 4. Using the Brake Drum Micrometer, measure the brake drum inside diameter. ^ Install a new brake drum if the maximum inside diameter exceeds the specification molded on the brake drum. 5. NOTE: If adjusting the rear brakes, refer to Brake Shoe Adjustment. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications Brake Shoe: Specifications Brake shoe lining wear limit ................................................................................................................. ................................................... 0.8 mm (0.03 inch) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Adjustments > Brake Shoe Adjustment - Drums Installed Brake Shoe: Adjustments Brake Shoe Adjustment - Drums Installed Brake Shoe Adjustment-Brake Drums Installed 1. Raise and support the vehicle. 2. At the back of the brake backing plate, remove the brake adjusting hole cover. 3. Rotate the brake shoe adjusting screw nut. 1 Using a screwdriver, move the brake shoe adjusting lever off the brake shoe adjusting screw nut. 2 NOTE: Move the adjustment tool handle upward to tighten the brake adjuster screw. Turn the brake shoe adjusting screw nut until the brake drum begins to drag. Then loosen the brake adjuster screw until the brake drum rotates freely. 4. Install a new brake adjusting hole cover. 5. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Adjustments > Brake Shoe Adjustment - Drums Installed > Page 6315 Brake Shoe: Adjustments Brake Shoe Adjustment - Drums Removed Brake Shoe Adjustment-Brake Drums Removed Special Tools Special Tool(s) WARNING: Asbestos fiber dust can be present on brake and clutch assemblies and is hazardous to health if inhaled. Brake and clutch assemblies must be cleaned using a vacuum cleaner recommended for use with asbestos fibers, such as a Brake/Clutch/Service Vacuum. The bag must be labeled per OSHA instructions, sealed, and the trash hauler notified as to the bag's contents. If a vacuum suitable for asbestos is not available, cleaning must be done wet. If dust generation is still possible, technicians must wear government-approved toxic dust purifying respirators. The Occupational Safety And Health Act (OSHA) requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians performing brake or clutch repair are to be present in the area. NOTE: After adjusting the rear brake shoes and linings check the parking brake for correct operation. Make sure the parking brake cable equalizer operates freely. 1. Measure the brake drum inside diameter. ^ Use a brake adjustment gauge. 2. Adjust the rear brake shoes and linings. ^ Rotate the brake adjuster screw until the rear brake shoes and linings touch the tool. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Adjustments > Page 6316 Brake Shoe: Service and Repair Shoes Special Tools Special Tool(s) Removal 1. Remove the brake drum. 2. Inspect the rear brake assembly for the following: ^ the rear wheel cylinder for excessive leakage that can contaminate brake system parts, and rebuild as necessary. ^ the rear brake shoes and linings for contamination, and install new shoes and linings as necessary. ^ the rear brake shoes and linings for minimum thickness, above the backing plate or rivets, and install new as necessary. ^ the springs for heat discoloration, and install new as necessary. ^ the adjusting lever contact with the brake adjuster screw. 3. NOTE: To aid installation, note the locations of the short and long brake shoe retracting springs. Remove the brake shoe retracting springs. 1 Remove the long brake shoe retracting spring. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Adjustments > Page 6317 2 Remove the short brake shoe retracting spring. 4. Remove the adjusting screw assembly. 1 Disconnect the brake shoe adjusting lever cable from the brake shoe adjusting lever. 2 Remove the brake shoe adjusting lever cable. 3 Remove the cable guide. 4 Remove the adjusting lever return spring and the brake shoe adjusting lever. 5 Remove the brake shoe adjusting screw spring. 6 Remove the brake adjuster screw assembly. 5. Remove the brake shoe anchor pin guide plate and the parking brake strut. 6. Remove the rear brake shoes and linings. 1 Remove the brake shoe hold-down springs. 2 Remove the rear brake shoes and linings. 3 Remove the brake shoe hold-down spring pins. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Adjustments > Page 6318 7. Pull back the parking brake cable spring and disconnect the parking brake lever. Installation 1. Compress the parking brake cable spring and attach the parking brake lever. 2. Clean and lubricate the brake backing plate. ^ Use Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A (Motorcraft WA-10) or an equivalent silicone compound meeting Ford specification ESE-M1C171-A. 3. Install the rear brake shoes and linings. 1 Position the rear brake shoes and linings. 2 Position the parking brake lever. 3 Install the brake shoe hold-down spring pins and the brake shoe hold-down springs. 4. Install the parking brake strut. 1 Install the parking brake link spring on the parking brake strut. 2 Install the parking brake strut. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Adjustments > Page 6319 3 Install the brake shoe anchor pin guide plate. 5. Install the short brake shoe retracting spring. 1 Place the brake shoe adjusting lever cable over the anchor pin, with crimped side in. 2 Install the short brake shoe retracting spring. 6. NOTE: Make sure the brake shoe adjusting lever cable is positioned in the cable guide groove. Install the long brake shoe retracting spring. 1 Install the cable guide. 2 Position the brake shoe adjusting lever cable in the cable guide groove. 3 Install the long brake shoe retracting spring. 7. NOTE: To prevent incorrect installation, the socket end of each brake adjuster screw is stamped R or L. Assemble the brake adjuster screw assembly. 1 Apply Silicone Brake Caliper Grease and Dielectric Compound D7AZ-l9A331-A (Motorcraft WA-10) or an equivalent silicone compound meeting Ford specification ESE-MIC171-A. 2 Install the brake adjuster screw into the brake show adjusting screw nut to the end of the threads, and then loosen one-half turn. 3 Install the brake shoe adjusting screw socket on the brake shoe adjusting screw nut. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Adjustments > Page 6320 8. Install the brake adjuster screw assembly. 1 Position the brake adjuster screw assembly. 2 Install the brake shoe adjusting screw spring. 3 Position the brake shoe adjusting lever cable. 4 Position the adjusting lever return spring and the brake shoe adjusting lever. 5 Hook the brake shoe adjusting lever cable to the brake shoe adjusting lever. 9. Test the operation of the automatic self-adjuster. 1 Pull the brake shoe adjusting lever cable and check that the brake shoe adjusting lever rotates the brake shoe adjuster assembly. 2 Release the brake shoe adjusting lever cable and check that the brake shoe adjusting lever advances to the next notch on the brake shoe adjusting screw nut. 10. Adjust the brakes. 11. Install the brake drum. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications Rear wheel cylinder bolts .................................................................................................................... ..................................................... 15 Nm (11 ft. lbs.) Brake bleeder screw ........................................ ....................................................................................................................................... 7-9 Nm (5-6 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications > Page 6324 Wheel Cylinder: Service and Repair Wheel Cylinder Removal and Installation 1. Remove the brake shoes and linings. 2. Remove the rear wheel cylinder. 1 Disconnect the brake line fitting. 2 Remove the two rear wheel cylinder bolts and remove the rear wheel cylinder. 3. To install, reverse the removal procedure. 4. Bleed the brake system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding Brake Bleeding: Service and Repair Brake Caliper Bleeding Caliper WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water to induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. 1. NOTE: It is not necessary to do a complete brake system bleed if only the disc brake caliper was disconnected. Place a box end wrench on the disc brake caliper bleeder screw. Attach a rubber drain tube to the disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3. Loosen the disc brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 4. Tighten the disc brake caliper bleeder screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6330 Brake Bleeding: Service and Repair Brake System Manual Bleeding Manual WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. NOTE: When any part of the hydraulic system has been disconnected for repair or installation of new components, air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 2. NOTE: Disc brake is shown, drum brake is similar. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 3. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6331 4. NOTE: Disc brake is shown, drum brake is similar. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH rear bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 5. Continue bleeding the system going in order from the LH rear bleeder screw to the RH front bleeder screw ending with the LH front bleeder screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6332 Brake Bleeding: Service and Repair Brake System Pressure Bleeding Pressure WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water to induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 2. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers of pressure bleeding equipment. Follow the instructions of the manufacturer when installing the adapter. Install the bleeder adapter to the brake master cylinder reservoir, and attach the bleeder tank hose to the fitting on the adapter. 3. NOTE: Disc brake is shown, drum brake is similar. NOTE: Bleed the longest line first. Make sure the bleeder tank contains enough specified brake fluid to complete the bleeding operation. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 4. Open the valve on the bleeder tank. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6333 5. NOTE: Disc brake is shown, drum brake is similar. Loosen the RH rear bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten the RH rear bleeder screw and remove the rubber hose. 6. Continue bleeding the rear of the system, going in order from the LH rear bleeder screw to the RH front bleeder screw, ending with the LH front bleeder screw. 7. Close the bleeder tank valve. Remove the tank hose from the adapter, and remove the adapter. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6334 Brake Bleeding: Service and Repair Four Wheel ABS Hydraulic Control Unit (HCU) Four Wheel Anti-Lock Brake System (4WABS) Hydraulic Control Unit (HCU) WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water to induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. NOTE: This procedure only needs to be carried out if a new 4-Wheel Anti-Lock Brake (4WABS) Hydraulic Control Unit (HCU) has been installed. 1. Connect the scan tool DCL cable adapter into the vehicle Data Link Connector (DLC) under the dash, and follow the scan tool instructions for bleeding. 2. Clean all dirt from and remove the brake master cylinder filler cap, and fill the brake master cylinder reservoir with the specified brake fluid. 3. NOTE: Disc brake is shown, drum brake is similar. Connect a clear drain tube to the RH rear bleeder screw and the other end in a container partially filled with recommended brake fluid. 4. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6335 5. NOTE: Disc brake is shown, drum brake is similar. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 6. Continue bleeding the system, going in order from the LH rear bleeder screw to the RH front bleeder screw, ending with the LH front bleeder screw. 7. Repeat the bleed procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6336 Brake Bleeding: Service and Repair Master Cylinder Priming - In-Vehicle or Bench Master Cylinder Priming-In-Vehicle or Bench Special Tool(s) WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake component and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or installation, air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. NOTE: When a new brake master cylinder has been installed or the system has been emptied or partially emptied, it must be primed to prevent air from entering the system. 1. For in-vehicle priming, disconnect the brake lines from the brake master cylinder. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6337 2. For bench priming, mount the brake master cylinder in a vise. 3. Install short brake tubes with the ends bent into the brake master cylinder reservoir. ^ Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A. 4. For a new brake master cylinder, loosen the brake pressure switch. 5. Slowly depress and hold the primary piston or, for in-vehicle driving, have an assistant slowly depress and hold the brake pedal. Tighten the brake pressure switch. 6. Repeat the above three steps until no air bubbles are visible in the expelled fluid. 7. Slowly depress the primary piston or, for in-vehicle priming, have an assistant slowly pump the brake pedal until clear brake fluid flows from both brake tubes with no air bubbles. 8. If necessary, install the brake master cylinder into the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6338 9. Remove the short brake tubes and install the master cylinder outlet tubes. 10. Loosen a brake outlet tube at the 4WABS Hydraulic Control Unit (HCU). 11. NOTE: Refill the brake master cylinder reservoir as necessary. Have an assistant depress and hold the brake pedal. Tighten the outlet tube fitting at the HCU. 12. Repeat the above three steps until no air bubbles are visible in the expelled brake fluid. 13. Repeat the above four steps for the remaining master cylinder outlet tube. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6339 14. Connect one end of a flexible tube to the master cylinder bleeder screw. Submerge the other end in a container partially filled with the specified brake fluid. 15. Have an assistant pump and then hold firm pressure on the brake pedal. 16. NOTE: Refill the brake master cylinder reservoir as necessary. Loosen the master cylinder bleeder screw until brake fluid flows out of the drain tube. 17. Tighten the master cylinder bleeder screw. 18. Repeat the above three steps until there are no air bubbles in the expelled brake fluid. 19. Bleed the brake system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Front Caliper bleeder screw, rear ................................................................................................................. .................................................. 20 Nm (15 ft. lbs.) Caliper bleeder screw, front ................................ .................................................................................................................................. 20 Nm (15 ft. lbs.) Front disc brake caliper anchor plate bolts ............................................................................................................................... 98-132 Nm (72-97 ft. lbs.) Disc brake caliper bolts .............................................................................................................................................................. 28-36 Nm (21-26 ft. lbs.) Rear Brake caliper bolts ............................................................................................................................... ................................................. 27 Nm (20 ft. lbs.) Caliper flow bolt ................................................... ..................................................................................................................... 30-40 Nm (23-29 ft. lbs.) Rear wheel disc brake adapter bolts ................................................................................................................................................... 108 Nm (80 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front Brake Caliper: Service and Repair Front Caliper Removal and Installation Caliper Removal 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. WARNING: Use of any other than approved DOT 3 brake fluid will cause damage to brake components and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: Do not clamp the brake hose. The hose can be damaged. Disconnect the front brake hose. 1 Remove the front brake hose bolt. 2 Disconnect the front brake hose. 3 Remove and discard the copper washers Plug the front brake hose. 4. Remove the disc brake caliper. 1 Remove the disc brake caliper bolts. 2 Lift the disc brake caliper off the front disc brake caliper anchor plate Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6345 5. Inspect the disc brake caliper for leaks. ^ If leaks are found, disassembly is required. Installation 1. Install the disc brake caliper. 1 Install the disc brake caliper. 2 Install the disc brake caliper bolts. 2. Install the front brake hose. ^ Use new copper washers; connect the front brake hose. ^ Install the front brake hose bolt. 3. Bleed the disc brake caliper. 4. Install the wheel and tire assembly. 5. Check the brake system for correct operation. Caliper Disassembly and Assembly Caliper Disassembly WARNING: Use of any brake fluid other than approved DOT 3 will cause permanent damage to brake components and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water to induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6346 water. NOTE: Use clean, fresh Ford High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or equivalent meeting Ford specification ESA-M6C25A ^ Do not reuse brake fluid drained or bled from the system. ^ Do not use brake fluid that has been stored in an open container. ^ Do not use contaminated brake fluid 1. Remove the disc brake caliper. 2. Drain remaining brake fluid from the disc brake caliper 3. Secure the disc brake caliper in a vise. 4. Remove the caliper pistons. 1 Place a block of wood between the caliper bridge and the caliper pistons. 2 Apply low air pressure to the fluid port in the disc brake caliper. 3 Force out the caliper piston to the block of wood. 4 Remove the block of wood and the caliper pistons. 5. Remove and discard the piston seals and boots. 6. NOTE: Do not hone the caliper bores. Pistons are not available for honed caliper bores. If the caliper bores are excessively scored or corroded, install a new disc brake caliper. Assembly 1. CAUTION: Never reuse piston seals or dust boots. NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been allowed to stand in an open container for an Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6347 extended period of time. Lubricate the piston boot, caliper piston, piston seal, and cylinder bores with High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A. 2. Install the caliper pistons. 1 Install the piston seal. 2 Install the piston boot. 3 CAUTION: Be careful not to damage or dislodge the piston seal. Insert the caliper piston. 4 Press the caliper piston into the caliper bore, being careful not to cock the caliper piston. 3. Install the disc brake caliper. Brake Caliper Anchor Plate Brake Caliper Anchor Plate Removal 1. NOTE: 4x4 is shown, 4x2 is similar. Remove the pads. 2. Remove the front disc brake caliper anchor plate. 1 Remove the two front disc brake caliper anchor plate bolts. 2 Remove the front disc brake caliper anchor plate. Installation 1. NOTE: Use new brake caliper anchor plate bolts when installing the brake caliper anchor plate. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6348 Install the front disc brake caliper anchor plate. 1 Position the front disc brake caliper anchor plate. 2 Install new front disc brake caliper anchor plate bolts. 2. Install the pads. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6349 Brake Caliper: Service and Repair Rear Caliper Removal and Installation Caliper Removal 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: Do not clamp the brake hose. The hose can be damaged. Disconnect the brake hose. 1 Remove the bolt. 2 Disconnect the rear wheel brake hose. 3 Remove the copper washers and plug the brake hose. 4. CAUTION: Do not remove the guide pins or guide pin boots unless a problem is suspected. The guide pins are meant to be sealed for life and are not repairable. Use Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A (Motorcraft WA-10) or an equivalent silicone compound meeting Ford specification ESE-MlC171-A for re-lubing the caliper slide pins. Other greases can swell the guide pin boots, resulting in contamination and accelerated corrosion or wear of the caliper slide pin mechanism. Remove the rear disc brake caliper. 1 Remove the brake caliper bolts. 2 Lift the rear disc brake caliper off the rear disc brake caliper anchor plate. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6350 5. Inspect the rear disc brake caliper for leaks. ^ If leaks are found, disassembly is required. Installation 1. CAUTION: To prevent interference with rear disc brake caliper operation, install only the correct caliper bolt. NOTE: Make sure the stainless steel shoe slippers are correctly positioned. Install new slippers if worn or damaged. NOTE: When installed, the locator notch on the brake pads will be located at the upper end of the rear disc brake caliper. Install the rear disc brake caliper. 2. Install the rear wheel brake hose. ^ Connect the brake hose and install the caliper flow bolt. ^ Use new copper washers. 3. Bleed the disc brake caliper. 4. Install the wheel and tire assembly. 5. Verify correct brake operation. Caliper Disassembly and Assembly Caliper Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6351 Special Tool(s) Disassembly WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water to induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. Remove the rear disc brake caliper. 2. Drain the remaining brake fluid from the rear disc brake caliper. 3. Secure the rear disc brake caliper in a vise. 4. Remove the rear disc brake piston. ^ Place a block of wood between the caliper bridge and the rear disc brake piston. ^ Apply low air pressure to the fluid port in the rear disc brake caliper. ^ Force the rear disc brake piston out to the block of wood. ^ Remove the block of wood and the rear disc brake piston. 5. NOTE: Do not hone the cylinder bore. Pistons are not available for honed cylinder bores. If the rear disc brake caliper cylinder bore/piston is excessively scored or corroded, install a new rear disc brake caliper. Remove and discard the piston seal and dust boot. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6352 Assembly CAUTION: Never reuse the piston seal or dust boot. NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been allowed to stand in an open container for an extended period of time. 1. Lubricate the following with High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. ^ cylinder bore ^ piston seal ^ rear disc brake piston ^ dust boot 2. Install the piston seal. 3. Install the dust boot. 4. CAUTION: Be careful not to damage or dislodge the piston seal. Install the rear disc brake piston. 5. Install the rear disc brake caliper. Rear Disc Brake Adapter Adapter Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6353 Removal and Installation 1. Disconnect the rear parking brake cable guide. 2. Remove the axle shaft. 3. Remove the bolts and the rear wheel disc brake adapter. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications High Performance DOT 3 Brake Fluid .............................................................................. C6AZ-19542-AB or meets Ford specification ESA-M6C25-A. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 6360 Connector View C124 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications Brake Hose/Line: Specifications Brake master cylinder tube fitting, front ........................................................................................................................................ 15-20 Nm (11-14 ft. lbs.) Brake master cylinder tube fitting, rear .......................................................................................................................................... 15-20 Nm (11-14 ft. lbs.) Brake line-to-rear wheel cylinder fitting ................................................................................................................................................... 18 Nm (13 ft. lbs.) Brake hose bolt ........................................................................................................... ................................................................... 30-40 Nm (23-29 ft. lbs.) Master cylinder brake tube nuts ............................................................................................................................................................. 17.5 Nm (13 ft. lbs.) Front brake hose bolt .......................................................................................... ...................................................................................... 35 Nm (26 ft. lbs.) Front brake hose bracket .............................................................................................................................................................. ............. 15 Nm (11 ft. lbs.) Front brake tube ....................................................................................... .............................................................................................. 17.5 Nm (13 ft. lbs.) Rear brake hose to caliper bolt ....................................................................................................................................... .......................... 35 Nm (26 ft. lbs.) Brake hose bracket to rear axle bolt ......................................................................................................................................................... 15 Nm (11 ft. lbs.) Rear brake tube fitting ................................................................................................. ....................................................................... 17.5 Nm (13 ft. lbs.) Inlet brake line to HCU nuts (M10-1) ...................................................................................................................................................... 23 Nm (17 ft. lbs.) Outlet brake line to HCU nuts (M12-1) .................................................................................................................................................... 18 Nm (13 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications Brake pressure switch ......................................................................................................................... ................................................... 17.5 Nm (13 ft. lbs.) Brake pressure control valve .......................... ....................................................................................................................................... 17.5 Nm (13 ft. lbs.) Hydraulic control unit (HCU) to bracket bolts ........................................................................................................................................ 8 Nm (71 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 6367 Hydraulic Control Assembly - Antilock Brakes: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Antilock Brakes / Traction Control Systems; Testing and Inspection. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 6368 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Hydraulic Control Unit Removal and Installation WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. Disconnect the battery ground cable. 2. Disconnect the electrical connector by lifting up on the release tab. 3. Disconnect the brake lines from the Hydraulic Control Unit (HCU). 4. Remove the HCU. 1 Remove the bolts. 2 Remove the HCU. 5. If necessary, remove the anti-lock brake control module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 6369 6. CAUTION: After the electronic hydraulic control unit is installed, it is necessary to bleed the hydraulic brake system. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. ^ Bleed the HCU. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications Brake Master Cylinder: Specifications Master cylinder bleeder screw ............................................................................................................. ..................................................... 13 Nm (10 ft. lbs.) Brake master cylinder nut ................................ ......................................................................................................................................... 23 Nm (17 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 6373 Brake Master Cylinder: Locations Brake Master Cylinder Components Part 1 of 2 Part 2 of 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 6374 Brake Master Cylinder: Adjustments Push Rod Adjustment 1. Remove the brake master cylinder. 2. CAUTION: Do not apply the brake pedal with the master cylinder removed from the booster. Adjust the power brake booster to brake master cylinder push rod, vacuum applied. 1 Measure the power brake booster to brake master cylinder push rod. 2 If necessary, adjust the screw to the correct length. 3. NOTE: Use new nuts when installing the brake master cylinder. Install the brake master cylinder. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Master Cylinder Brake Master Cylinder: Service and Repair Brake Master Cylinder Master Cylinder Removal and Installation WARNING: Use of any other brake fluid than approved DOT 3 will cause permanent damage to brake components and will render the brakes inoperative. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. On cruise control equipped vehicles, disconnect the brake pressure switch. 2. Disconnect the brake fluid level warning switch. 3. Disconnect the two brake lines, and plug the lines and the brake master cylinder ports. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Master Cylinder > Page 6377 4. Remove the wiring retainer clip from the master cylinder. 5. Remove the nuts and the brake master cylinder. 6. To install, reverse the removal procedure. ^ Bleed the brake master cylinder before installation. ^ Bleed the brake system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Master Cylinder > Page 6378 Brake Master Cylinder: Service and Repair Brake Fluid Reservoir Reservoir Removal and Installation WARNING: Use of any other brake fluid than approved DOT 3 will cause permanent damage to brake components and will render the brakes inoperative. WARNING: Brake fluid contains polyglycols ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface immediately wash it with water. 1. Disconnect the brake master cylinder fluid level warning switch. 2. Use a suitable suction device to drain the brake master cylinder reservoir. 3. Carefully pry up on the brake master cylinder reservoir to remove. 4. NOTE: Whenever installing a new brake master cylinder reservoir, install new grommets. Install the brake master cylinder reservoir. 1 Lubricate the two grommets with High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A, and insert the grommets in the brake master cylinder. 2 Press the brake master cylinder reservoir into the grommets until it snaps. 3 Connect the brake master cylinder fluid level warning switch. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Master Cylinder > Page 6379 4 Fill the brake master cylinder reservoir with High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications Rear wheel cylinder bolts .................................................................................................................... ..................................................... 15 Nm (11 ft. lbs.) Brake bleeder screw ........................................ ....................................................................................................................................... 7-9 Nm (5-6 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications > Page 6383 Wheel Cylinder: Service and Repair Wheel Cylinder Removal and Installation 1. Remove the brake shoes and linings. 2. Remove the rear wheel cylinder. 1 Disconnect the brake line fitting. 2 Remove the two rear wheel cylinder bolts and remove the rear wheel cylinder. 3. To install, reverse the removal procedure. 4. Bleed the brake system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Specifications Parking Brake Cable: Specifications Parking brake cable and conduit clip bolt ....................................................................................................................................... 15-20 Nm (11-14 ft. lbs. Parking brake cable retainer clip bolt ................................................................................................................................................. 6-8 Nm (54-70 ft. lbs.) Parking brake cable retainer screws .......................................................................................................................................................... 20 Nm (15 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front Parking Brake Cable: Service and Repair Cable and Conduit - Front Cable and Conduit-Front Removal and Installation 1. Remove the parking brake control. 2. Remove the parking brake anchor pin from the parking brake control. 3. Bend the take up spool tab up. 4. Remove the front parking brake cable and conduit housing. 1 Compress the front parking brake cable and conduit-to-parking brake control clip. 2 Remove the front parking brake cable and conduit housing. 5. To install, reverse the removal procedure. ^ Make sure cable is routed through loop on takeup spool. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front > Page 6390 Parking Brake Cable: Service and Repair Cable and Conduit - Rear Cable and Conduit-Rear Removal All vehicles 1. NOTE: Make sure the parking brake control is fully released. Relieve the tension on the parking brake system. 1 Pull the front parking brake cable and conduit. 2 Insert a 4 mm (5/32 inch) drill bit or equivalent retainer into the parking brake control. 2. Remove the tire and wheel assembly. 3. NOTE: Disconnect the parking brake intermediate cable from the locating hole end of the connector. Disconnect the parking brake intermediate cable from the LH parking brake rear cable and conduit. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front > Page 6391 4. Separate the RH parking brake rear cable and conduit from the LH parking brake rear cable and conduit at the parking brake cable equalizer. Vehicles with drum brakes 5. Remove the screws. All vehicles 6. Remove the RH parking brake rear cable and conduit to LH parking brake rear cable and conduit clip. 7. Remove the RH parking brake rear cable and conduit from the parking brake cable bracket. 1 Compress the parking brake cable clip. 2 Remove the RH parking brake rear cable and conduit from the parking brake cable bracket. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front > Page 6392 Vehicles with rear disc brakes 8. Remove the RH parking brake rear cable and conduit from the rear parking brake cable retainer. All vehicles 9. Remove the RH parking brake rear cable and conduit to the RH hydraulic brake line clip. 10. Remove the parking brake cable retainer clip. 1 Remove the parking brake cable retainer clip bolt. 2 Remove the parking brake cable retainer clip. 11. Unclip the parking brake rear cable and conduit from the brake line clip on top of the rear axle housing. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front > Page 6393 Vehicles with rear disc brakes 12. Compress the retainer and release the parking brake rear cable and conduit from the rear disc brake caliper anchor plate. 13. Unclip the parking brake rear cable and conduit from the parking brake lever. 14. Remove the secondary brake shoe. 15. NOTE: It is not necessary to disconnect the parking brake lever from the brake shoe. Disconnect the cable from the parking brake lever. 16. Compress the retainer and remove the cable and conduit. Installation Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front > Page 6394 Vehicles with rear disc brakes 1. Clip the parking brake rear cable and conduit to the parking brake lever. 2. Connect the parking brake rear cable and conduit to the rear disc brake caliper anchor plate. Vehicles with rear drum brakes 3. Secure the brake cable retainer to the backing plate. 4. Install the secondary brake shoe. All vehicles 5. Clip the parking brake rear cable and conduit to the brake line clip on top of the rear axle housing. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front > Page 6395 6. Install the parking brake cable retainer clip. 1 Position the parking brake cable retainer clip. 2 Install the parking brake cable retainer clip bolt. 7. Install the RH parking brake rear cable and conduit to the RH hydraulic brake line clip. Vehicles with rear disc brakes 8. Hook the RH parking brake rear cable and conduit to the rear parking brake cable retainer. All vehicles 9. Connect the RH parking brake rear cable and conduit to the parking brake cable bracket. 1 Install the RH parking brake rear cable and conduit to the parking brake cable bracket. 2 Push the RH parking brake rear cable and conduit into the parking brake cable bracket until the parking brake cable and conduit clip is seated. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front > Page 6396 10. Install the RH parking brake rear cable and conduit to the LH parking brake rear cable and conduit clip. Vehicles with rear drum brakes 11. Install the screws. All vehicles 12. Connect the RH parking brake rear cable and conduit to the LH parking brake rear cable and conduit at the parking brake cable equalizer. 13. Connect the parking brake intermediate cable to the LH parking brake rear cable and conduit. 14. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Install the front wheel and tire assemblies. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front > Page 6397 15. Apply tension to the parking brake system. 1 Pull down on the front parking brake cable and conduit. 2 Remove the retainer from the parking brake control. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications Parking Brake Control: Specifications Parking brake control bolts ............................................................................................................................................................ 17-23 Nm (13-17 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 6401 Parking Brake Control: Service and Repair Control Removal and Installation 1. Remove the LH cowl side trim panel. 2. NOTE: Verify that the parking brake control is fully released. Relieve the tension on the parking brake system. 1 Pull down on the parking brake intermediate cable. 2 Insert a 4 mm (5/32 inch) drill bit or equivalent retainer in the parking brake control. 3. Raise and support the vehicle. 4. Disconnect the front parking brake cable and conduit at the locating hole end of the connector. 5. Remove the front parking brake cable and conduit from the bracket. 1 Compress the retainer from the front parking brake cable and conduit from the bracket. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 6402 2 Remove the front parking brake cable and conduit from the bracket. 6. Lower the vehicle. 7. Remove the screws and the instrument panel steering column cover. 8. Remove the parking brake release mounting bolts. 9. Loosen the bolt and disconnect the instrument panel-to-body harness electrical connector. 10. Remove the parking brake control and front parking brake cable and conduit. ^ Disconnect the parking brake signal switch electrical connector. ^ Remove the three parking brake control bolts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 6403 11. Remove the screw and position the bracket and wiring connector aside. 12. Remove the parking brake anchor pin from the parking brake control. 13. Bend the takeup spool tab up. 14. Remove the front parking brake cable and conduit housing. 1 Compress the front parking brake cable and conduit-to-parking brake control clip. 2 Remove the front parking brake cable and conduit housing. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 6404 15. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Switch > Component Information > Specifications Parking Brake Release Switch: Specifications Parking brake remote release to instrument panel .................................................................................................................... 2.1-2.9 Nm (19-25 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair Parking Brake Shoe: Service and Repair Shoes Special Service Tool(s) Special Tool(s) Removal 1. NOTE: Make sure the parking brake control is fully released. Relieve the tension on the parking brake system. 1 Pull the front parking brake cable and conduit. 2 Insert a 4 mm (5/32 inch) drill bit or equivalent retainer. 2. Raise and support the vehicle. 3. Remove the tire and wheel assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Page 6411 4. Remove the rear brake disc. 5. Remove the brake shoe retracting spring. 6. Remove the brake shoe adjusting screw spring. 7. Remove the brake adjuster screw. 8. Remove the rear brake shoe hold-down springs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Page 6412 9. Remove the rear brake shoes and linings along with the inboard brake shoe retracting spring. 10. Inspect the components for excessive wear or damage and install new as required. Installation 1. NOTE: Lubricate the brake shoe contact point before installation of rear shoes using Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A (Motorcraft WA-10) or an equivalent silicone compound meeting Ford specification ESE-M1C171-A. Install the rear brake shoes and linings along with the inboard brake shoe retracting spring. 2. Install the brake shoe hold-down springs. 3. Install the brake adjuster screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Page 6413 4. Install the brake shoe adjusting screw spring. 5. Install the outboard brake shoe retracting spring. 6. Use Brake Adjusting Gauge to measure the inside diameter of the drum portion of the rear brake disc. 7. Use Brake Adjusting Gauge to set the rear brake shoe and lining diameter to 0.5 mm (0.020 inch) less than the inside diameter of the drum portion of the rear brake disc. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Page 6414 8. Install the rear brake disc. 9. WARNING: Always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel. Installing wheels without correct metal to metal contact at the wheel mounting surfaces can cause the wheel nuts to loosen and come off while the vehicle is in motion, causing loss of control. Clean the wheel hub mounting surface. 10. Install the wheel and tire assembly. 11. Apply tension to the parking brake cable system. 1 Hold the front parking brake cable and conduit taut. 2 Remove the retainer from the parking brake control. 12. Check operation of the parking brake. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Diagrams Connector View C2015 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 6422 Vacuum Brake Booster: Description and Operation Brake Booster The power brake booster: ^ is a dual diaphragm, vacuum assisted power brake booster. ^ is located on the RH side of the bulkhead in the engine compartment, between the brake pedal and brake master cylinder. ^ is divided into separate chambers by the diaphragms. ^ will not operate if vacuum is restricted or if any of the vacuum related power brake components fail. ^ is installed as an assembly. If the power assist fails, the brake system will continue to operate with increased brake pedal effort. Hose and Check Valve The power brake booster check valve: ^ is located on the front of the power brake booster. ^ is positioned between the power brake booster and the power brake booster hose. ^ closes when the engine is turned off. ^ in the closed position, traps engine vacuum in the power brake booster. ^ retains vacuum to provide several power assisted brake applications with the engine off. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 6423 Vacuum Brake Booster: Service and Repair Brake Booster Removal 1. Remove the brake master cylinder. 2. Disconnect the power brake booster hose. 1 Compress the clamp. 2 Disconnect the power brake booster hose. 3. Disconnect the brake pedal to power brake booster push rod. 1 Remove the self-locking pin. 2 Remove the stoplight switch and the brake booster push rod from the brake pedal pin. Remove the brake booster push rod bushing. 4. Remove the bulkhead sound insulator. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 6424 5. NOTE: Support the power brake booster. Remove the power brake booster. 1 Remove the nuts. 2 Remove the power brake booster. Installation 1. Follow the removal procedure in reverse order. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications Electronic Brake Control Module: Specifications Control module bolts ............................................................................................................................ ................................................ 1.5 Nm (13 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 6429 View 151-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 6430 Connector View C135 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 6431 Electronic Brake Control Module: Service and Repair Module-Anti-Lock Brake Control Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the electrical connectors. 3. Remove the anti-lock brake control module. 1 Remove the bolts. 2 Remove the anti-lock brake control module. 4. CAUTION: Once the new module is installed, the module configuration information may have to be entered. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms can occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 6432 To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 6437 Connector View C124 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Differential Speed Sensor > Component Information > Locations View 151-16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Differential Speed Sensor > Component Information > Locations > Page 6441 Connector View C455 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Specifications Parking Brake Release Switch: Specifications Parking brake remote release to instrument panel .................................................................................................................... 2.1-2.9 Nm (19-25 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Diagrams Connector View C2015 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications Front anti-lock brake sensor bolt ........................................................................................................................................................... (12 Nm) (8.5 ft. lbs.) Rear anti-lock brake sensor bolt ............................................................................................................................................................. (27 Nm) (20 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left front View 151-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left front > Page 6453 View 151-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front Connector View C150 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 6456 Connector View C160 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front Wheel Speed Sensor: Service and Repair Sensor, Front Sensor-Front Removal and Installation 1. Raise and support the vehicle. 2. Disconnect the front anti-lock brake sensor wire from the vehicle frame. 1 Disconnect the electrical connector. 2 Unclip the front anti-lock brake sensor wire from the vehicle frame. 3. Remove the front anti-lock brake sensor. 1 Remove the bolt. 2 Remove the front anti-lock brake sensor. 4. NOTE: Plug the sensor mount opening and thoroughly clean the mounting surface. Apply High-Temperature 4x4 Front Axle and Wheel Bearing Grease E8TZ-19590-A meeting Ford Specification ESA-MIC198-A. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front > Page 6459 Wheel Speed Sensor: Service and Repair Sensor, Rear Sensor-Rear Removal and Installation 1. Raise and support vehicle. NOTE: Clean off dirt and foreign material that may have collected around the rear anti-lock brake sensor before removal. 2. Remove the rear anti-lock brake sensor. 1 Disconnect the rear anti-lock brake sensor electrical connector. 2 Remove the bolt. 3 Remove the rear anti-lock brake sensor. 3. NOTE: Thoroughly clean the mounting surface. NOTE: Inspect the anti-lock brake sensor O-ring for damage; lightly lubricate the O-ring with SAE 75W-140 High Performance Rear Axle Lubricant FITZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Diagrams Connector View C257 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Specifications Ignition Switch Lock Cylinder: Specifications Lock Cylinder Housing Screws ............................................................................................................ .................................................... 22 Nm (16 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder-Functional Lock Cylinder Removal 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock cylinder. 3. To install, reverse the removal procedure. ^ Verify ignition switch lock cylinder operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 6471 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional Ignition Switch Lock Cylinder-Non-Functional Lock Cylinder Removal and Installation 1. NOTE: Make sure the front wheels are in the straight-ahead position. Disconnect the battery ground cable and wait at least one minute. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes and instructions in the steering wheel removal and installation procedure. Remove the steering wheel assembly. 3. Twist off the cap from the ignition switch cylinder. 4. NOTE: The lock cylinder is repaired by discarding the inoperative lock cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code oil the vehicle. Remove the ignition switch lock cylinder. ^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. ^ Use a 3/8-inch drill bit to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. ^ Remove and discard the ignition switch lock cylinder and clean the drill shavings from the steering column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 6472 5. Remove the bearing retainer. 6. Remove the bearing and gear. ^ Thoroughly clean all drill shavings from the steering column and inspect it for damage. 7. To install, reverse the removal procedure. ^ Install a new ignition switch lock cylinder. ^ Verify ignition switch lock cylinder operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Digital Transmission Range Sensor <--> [Neutral Safety Switch] > Component Information > Locations View 151-5 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Digital Transmission Range Sensor <--> [Neutral Safety Switch] > Component Information > Locations > Page 6476 Connector View C167 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Digital Transmission Range Sensor <--> [Neutral Safety Switch] > Component Information > Locations > Page 6477 Digital Transmission Range Sensor: Description and Operation Digital Transmission Range (TR) Sensor The digital Transmission Range (TR) sensor is located on the outside of the transmission at the manual lever. The digital TR sensor completes the start circuit in PARK, NEUTRAL, and the back-up lamp circuit in REVERSE. The digital TR sensor also opens and closes a set of four switches that are monitored by the Powertrain Control Module (PCM) to determine the position of the manual lever (P, R, N, (D), 3, 2, 1). See: Powertrain Management/Computers and Control Systems/Sensors and Switches - Computers and Control Systems/Digital Transmission Range Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 6482 Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 6483 Connector View C1017 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 6484 Starter Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 6485 Relay - Micro ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins > Battery - Battery Eye Function/Charging/Service Battery: Technical Service Bulletins Battery - Battery Eye Function/Charging/Service TSB 07-5-8 03/19/07 BATTERY SERVICE - OPERATION OF BATTERY EYE - CHARGING SERVICE TIPS FORD: 1999-2003 Escort 2000-2006 Taurus 2000-2007 Crown Victoria, Focus, Mustang 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 2000-2003 Windstar 2000-2004 Explorer Sport 2000-2006 Excursion 2000-2007 E-Series, Expedition, Explorer, F-150, F-250 Light Duty, F-53 Motorhome Chassis, F-Super Duty, Ranger 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004-2006 Freestar 2005-2007 Escape Hybrid 2007 Edge 2000-2007 F-650, F-750 2006 Low Cab Forward LINCOLN: 1998-2002 Continental 2000-2006 Lincoln LS 2000-2007 Town Car 2006 Zephyr 2007 MKZ 2000-2007 Navigator 2002 Blackwood 2003-2005 Aviator 2006-2007 Mark LT, Mark LT 2007 MKX MERCURY: 1999-2002 Cougar 2000-2005 Sable 2000-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 2000-2002 Villager 2000-2007 Mountaineer 2004-2006 Monterey 2004-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 06-4-2 to update the vehicle model years. ISSUE This TSB describes the operation and function of the Battery Eye and correct Battery Recharging procedures. ACTION Refer to the following Service Tips to avoid misdiagnosis of a battery using the Battery Eye, and to determine the best way to charge a battery that may be discharged. SERVICE TIPS Battery Eye Operation / Function Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins > Battery - Battery Eye Function/Charging/Service > Page 6490 The purpose of the battery eye is to indicate the state of charge of the battery in the assembly plant and while on the dealership lot. The battery eye can also indicate the state-of-charge when the vehicle is delivered to the dealership and during the pre-delivery inspection process. The battery eye is made up of a viewing plate, two balls and a small passage. The balls indicate the specific gravity of the electrolyte by floating higher or lower in the passageway. It is important to note that the battery eye checks the specific gravity on only one battery cell. ^ RED usually indicates that the battery state-of-charge is at 40 percent or less ^ YELLOW indicates that the battery state-of-charge is between 40 and 57 percent ^ GREEN indicates that the battery state-of-charge is above 57 percent ^ NO COLOR/BLACK sometimes no color can be seen at all and the eye appears black. This could happen after the battery has been in service for several years and some of the plate material has coated the balls ^ CLEAR could happen if the battery case becomes damaged and the electrolyte has fallen below the plates The battery eye is a state-of-charge indicator, but should not be used to condemn a battery after the vehicle has been placed in service. After delivery, many things could happen to cause the battery eye to lead to misdiagnosis of the battery's actual state-of-charge. After the vehicle has been in service, the battery eye does not always accurately reflect the battery state-of-charge. The GR-1 190 Battery Tester/Charge or Micro 490 Digital Battery Analyzer should be used to determine battery condition. Do not replace a battery based solely on the indication given by the battery eye. The battery eye color simply indicates the battery state-of-charge, not its condition. If the eye indicates the battery may be discharged, Use GR-1 190 Battery Tester/Charger to determine the battery condition or recharge the battery before testing using the Micro 490. A red or yellow indicator usually means that the battery is discharged, not defective. Therefore, a battery with a red or yellow eye should not automatically be replaced. The indicator could remain red after recharge because the balls are stuck in the passageway. When new vehicles are delivered to the dealership, be sure to check the state-of-charge indicator within 72 hours. If the battery eye is red, charge the battery until it is fully charged. Refer to the following Battery Charging Procedure. Batteries discharge while the vehicle is on the lot due to normal parasitic key-off loads. Also, vehicles in inventory are generally driven short distances with heavy electrical loads. Over a period of time (30 days or more), vehicles still in inventory will have shallow to deeply discharged batteries. The vehicle's charging system is designed to supply the vehicle's electrical power needs and maintain the battery near full charge during normal vehicle use. The charging system is not capable of bringing a deeply discharged battery back near full charge in a short amount of time such as allowing the vehicle to idle for 15 minutes to "recharge the battery". Discharged batteries should be charged using an external charger. Refer to the following Battery Charging Procedure. NOTE THE BATTERY EYE MAY REMAIN RED FOR A PERIOD OF TIME (UP TO SEVERAL DAYS), EVEN AFTER THE BATTERY IS FULLY CHARGED, BECAUSE THE ACID IS NOT YET FULLY MIXED. Battery Charging Procedure Dealers with GR-1 190, use the Diagnostic Fast Charge Mode on GR-1 190 for this procedure and for dealers without a GR-1 190 the following procedure applies: The Micro 490 Digital Battery Analyzer (Rotunda Part Number 162-00004) is extremely accurate if used properly and can distinguish the difference between good, defective, worn out, or discharged-only batteries. This TSB provides proper battery charging procedures for batteries that are identified as "discharged-only". Discharged-only batteries can be recharged using the procedures in this TSB without reducing battery life or charge capacity. NOTE BATTERY CHARGERS HAVE IMPROVED GREATLY WITH THE ADDITION OF THE NEW GENERATION OF "PULSE CHARGERS". THESE NEW CHARGERS PULSE CURRENT INTO THE BATTERY THAT BREAKS DOWN THE SULFATION LAYER ON THE BATTERY PLATES AND GENERALLY REDUCE CHARGING TIMES TO LESS THAN 1 HOUR. ^ DEEPLY DISCHARGED - A battery that is drained over a prolonged period of time such as an unsold vehicle, to the point it is dead ^ SHALLOW DISCHARGE - A battery that is drained by leaving an accessory on for several hours or a few days, and has a very low charge Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins > Battery - Battery Eye Function/Charging/Service > Page 6491 The chart information summarizes two (2) recommended methods of charging. NOTE COLD BATTERIES WILL NOT READILY ACCEPT A CHARGE. THEREFORE, BATTERIES SHOULD BE ALLOWED TO WARM TO APPROXIMATELY 41° F (5° C) BEFORE CHARGING. THIS MAY REQUIRE 4 TO 8 HOURS AT ROOM TEMPERATURE. A battery which has been completely discharged and left in that condition for a prolonged time (such as an unsold vehicle) may be slow to accept a charge initially, and in some cases may not accept a charge at the normal charger setting. When batteries are in this condition, charging can be started by use of the "dead battery" feature on chargers so equipped. Follow charger manufacturer's instructions for use of dead battery switch. If switch is the spring-loaded type, it may need to be held in the ON position for up to 3 minutes. NOTE THE BATTERY EYE MAY REMAIN RED FOR A PERIOD OF TIME (UP TO SEVERAL DAYS), EVEN AFTER THE BATTERY IS FULLY CHARGED, BECAUSE THE ACID IS NOT YET FULLY MIXED. For additional information, refer to the PTS Website, web based Technician training "Fix It Right The First Time" course "Battery Testing and Charging 34G02W0" (website). WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT070508 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 10655 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Specifications > Electrical Specifications Battery: Electrical Specifications Parasitic Draw (Current Drain) ............................................................................................................................................................ Less Than 0.03 amps NOTE: For testing procedures, please refer to Battery Drain Test. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Specifications > Electrical Specifications > Page 6494 Torque Specifications Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Specifications > Page 6495 Battery: Diagrams Connector View C1100a Connector View C1100b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Service Precautions > Technician Safety Information Battery: Technician Safety Information WARNING: ^ BATTERIES NORMALLY PRODUCE EXPLOSIVE GASES WHICH CAN CAUSE PERSONAL INJURY. THEREFORE, DO NOT ALLOW FLAMES, SPARKS OR LIGHTED SUBSTANCES TO COME NEAR THE BATTERY, ALWAYS SHIELD YOUR FACE AND PROTECT YOUR EYES. ALWAYS PROVIDE VENTILATION. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR INSTALLING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE REPAIRING, INSTALLING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. FAILURE TO FOLLOW THESE PROCEDURES MAY RESULT IN PERSONAL INJURY. REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ WHEN LIFTING A BATTERY, EXCESSIVE PRESSURE ON THE END WALLS COULD CAUSE ACID TO SPEW THROUGH THE VENT CAPS, RESULTING IN PERSONAL INJURY. LIFT WITH A BATTERY CARRIER OR WITH YOUR HANDS ON OPPOSITE CORNERS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ KEEP OUT OF THE REACH OF CHILDREN. BATTERIES CONTAIN SULFURIC ACID. AVOID CONTACT WITH SKIN, EYES OR CLOTHING. ALSO, SHIELD YOUR EVES WHEN WORKING NEAR THE BATTERY TO PROTECT AGAINST POSSIBLE SPLASHING OF THE ACID SOLUTION. IN CASE OF ACID CONTACT WITH THE SKIN OR EYES, FLUSH IMMEDIATELY WITH WATER FOR A MINIMUM OF 15 MINUTES AND GET PROMPT MEDICAL ATTENTION. IF ACID IS SWALLOWED, CALL A PHYSICIAN IMMEDIATELY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ DO NOT ATTEMPT BATTERY DRAIN TEST ON A LEAD-ACID BATTERY THAT HAS RECENTLY BEEN RECHARGED. EXPLOSIVE GASES CAN CAUSE PERSONAL INJURY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Service Precautions > Technician Safety Information > Page 6498 Battery: Vehicle Damage Warnings CAUTION: To prevent damage to the ammeter, do not crank the engine or operate accessories that draw more than 10A. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Service Precautions > Page 6499 Battery: Description and Operation Vehicles are equipped with a 12 volt maintenance-free battery. The battery and cable system consists of the following components: ^ battery ^ battery cable assembly ^ battery tray Environmental Protection Ford Motor Company strongly recommends that lead-acid batteries be returned to an authorized recycling facility for disposal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Battery: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the system. Visual Inspection Chart 2. Visually inspect for obvious signs of mechanical or electrical damage. 3. If an obvious cause for a concern is found, correct the cause before proceeding to the next step. 4. If the fault is not visually evident proceed to the pinpoint test. See: Pinpoint Tests Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6502 A1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6503 Battery: Component Tests and General Diagnostics Battery Drain Test NOTE: No production vehicle should have more than a 50 mA (0.050 amp) continuous draw. Check for current drains on the battery in excess of 50 milliampere (0.050 amp) with all the electrical accessories off and the vehicle at rest. Current drains can be tested with the following procedure: WARNING: DO NOT ATTEMPT THIS TEST ON A LEAD-ACID BATTERY THAT HAS RECENTLY BEEN RECHARGED. EXPLOSIVE GASES CAN CAUSE PERSONAL INJURY. CAUTION: To prevent damage to the meter, do not crank the engine or operate accessories that draw more than 10A. NOTE: ^ Many modules draw 10 mA (0.010 amp) or more continuously. ^ Use an in-line ammeter between the battery positive or negative post and its respective cable. ^ Typically, a drain of approximately one amp can be attributed to an engine compartment lamp, glove compartment lamp, or luggage compartment lamp staying on continually. Other component failures or wiring shorts may be located by selectively pulling fuses to pinpoint the location of the current drain. When the current drain is found, the meter reading will fall to an acceptable level. If the drain is still not located after checking all the fuses, it may be due to the generator. ^ To accurately test the drain on a battery, an in-line digital ammeter must be used. Use of a test lamp or voltmeter is not an accurate method due to the number of electronic modules. 1. Make sure the junction box/fuse panels are accessible without turning on interior and underhood lights. 2. Drive the vehicle at least five minutes and over 48 km/h (30 mph) to turn on and exercise the vehicle systems. 3. Allow the vehicle to sit with the key off for at least 40 minutes to allow modules to time out/power down. 4. Connect a fused jumper wire between the negative battery cable and the negative battery post to prevent modules from resetting and to catch capacitive drains. 5. Disconnect the negative battery cable from the post without breaking the connection of the jumper wire. 6. Connect the tester between the negative battery cable and the post. The meter must be capable of reading milliampere and should have a 10 amp capability. NOTE: It is very important that continuity is not broken between the battery and the negative battery cable when connecting the meter. If this happens, the entire procedure must be repeated. 7. Remove the jumper wire. NOTE: If the meter settings need to be switched or the test leads need to be moved to another jack, the jumper wire must be reinstalled to avoid breaking continuity. NOTE: ^ Amperage draw will vary from vehicle to vehicle depending on the equipment package. Compare to a comparable vehicle for reference. ^ No production vehicle should have more than a 50 mA (0.050 amp) draw. 8. If the draw is found to be excessive, pull fuses from the battery/central junction box one at a time and note the current drop. Do not reinstall the fuses until you are finished testing. 9. Check the wiring schematic in the wiring diagram for any circuits that run from the battery without passing through the battery/central junction box . Disconnect these circuits if the draw is still excessive. Battery Load Test 1. With the engine running, turn the A/C on, the blower motor on high speed and the headlamps on high beam. 2. Increase the engine speed to approximately 2000 rpm. The voltage should increase a minimum of 0.5 volt above the base voltage. ^ If the voltage does not increase as specified, carry out the Generator On-Vehicle Tests. See: Charging System/Testing and Inspection/Component Tests and General Diagnostics/Generator Testing ^ If the voltage increases as specified, the charging system is operating normally. Electronic Drains That Shut Off When The Battery Cable Is Disconnected 1. Repeat the steps of the battery drain testing. 2. Make sure all doors are closed and accessories are off. Without starting the engine, turn the ignition switch to RUN for a moment and then OFF. Wait a few minutes for the illuminated entry lamps to turn off if equipped. 3. Connect the ammeter and read the amperage draw. Test Conclusion Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6504 The current reading (current drain) should be less than 50 mA (0.05 amp). If the current drain exceeds 50 mA (0.05 amp) after a few minutes, and if this drain did not show in previous tests, the drain is most likely caused by an inoperative electronic component. As in previous tests, remove the fuses from the battery/central junction box one at a time to locate the problem circuit. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6505 Micro 490 Digital Battery Analyzer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Service and Repair > General Procedures Battery: Service and Repair General Procedures WARNING: ^ BATTERIES NORMALLY PRODUCE EXPLOSIVE GASES WHICH CAN CAUSE PERSONAL INJURY. THEREFORE, DO NOT ALLOW FLAMES, SPARKS OR LIGHTED SUBSTANCES TO COME NEAR THE BATTERY, ALWAYS SHIELD YOUR FACE AND PROTECT YOUR EYES. ALWAYS PROVIDE VENTILATION. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR INSTALLING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE REPAIRING, INSTALLING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. FAILURE TO FOLLOW THESE PROCEDURES MAY RESULT IN PERSONAL INJURY. REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ WHEN LIFTING A BATTERY, EXCESSIVE PRESSURE ON THE END WALLS COULD CAUSE ACID TO SPEW THROUGH THE VENT CAPS, RESULTING IN PERSONAL INJURY. LIFT WITH A BATTERY CARRIER OR WITH YOUR HANDS ON OPPOSITE CORNERS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ KEEP OUT OF THE REACH OF CHILDREN. BATTERIES CONTAIN SULFURIC ACID. AVOID CONTACT WITH SKIN, EYES OR CLOTHING. ALSO, SHIELD YOUR EVES WHEN WORKING NEAR THE BATTERY TO PROTECT AGAINST POSSIBLE SPLASHING OF THE ACID SOLUTION. IN CASE OF ACID CONTACT WITH THE SKIN OR EYES, FLUSH IMMEDIATELY WITH WATER FOR A MINIMUM OF 15 MINUTES AND GET PROMPT MEDICAL ATTENTION. IF ACID IS SWALLOWED, CALL A PHYSICIAN IMMEDIATELY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Disconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven to relearn its strategy. 2. Disconnect the positive battery cable. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Service and Repair > General Procedures > Page 6508 Battery: Service and Repair Removal and Installation Battery REMOVAL 1. Disconnect the battery cables. 2. Remove the battery heat shield. 3. Remove the hold-down bolt and the bracket. 4. Remove the battery. WARNING: WHEN LIFTING A BATTERY, EXCESSIVE PRESSURE ON THE END WALLS COULD CAUSE ACID TO SPEW THROUGH THE VENT CAPS. RESULTING IN PERSONAL INJURY. LIFT WITH A BATTERY CARRIER OR WITH YOUR HANDS ON OPPOSITE CORNERS. INSTALLATION 1. To install, reverse the removal procedure. Battery Tray REMOVAL 1. Remove the battery. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Service and Repair > General Procedures > Page 6509 2. Remove the battery ground cable to battery tray pin-type retainer. 3. Remove the cable to battery tray pin-type retainer. 4. Remove the bolt and the nut. 5. Remove the battery tray. 1 Remove the bolt. 2 Remove the battery tray. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Service and Repair > Page 6510 Micro 490 Digital Battery Analyzer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Specifications > Electrical Specifications Generator: Electrical Specifications Item....................................................................................................................................................... ..............................................................Specification Battery ................................................................................................................................................. .................................................................. 72 amp/hr Generator ........................................................ ......................................................................................................................................................... 130 amp Generator Output (Minimum) .......................................................................................................................................................... 58 Amps at 2,000 RPM Generator Output .......................................................................................... ............................................................................ 13 - 15 Volts at 2,000 RPM Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Specifications > Electrical Specifications > Page 6516 Torque Specifications Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions Generator: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. NOTE: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 6519 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number or the component name in one of the the A-Z Component Lists, the Component Location description for that component can easily be found. See: Locations/Component Locations/A-Z Component List Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 6520 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 6521 the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 6522 that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 6523 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 6524 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 6525 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 6526 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 6527 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 6528 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 6529 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 6530 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 6531 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 6532 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 6533 Systems Overview Wire Color Code Identification Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 6534 OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 6535 Generator: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 6536 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 6537 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 6538 Generator: Connector Views Connector View C102a Connector View C102b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Description and Operation > Standard Models (Non BI-Fuel) Generator: Description and Operation Standard Models (Non BI-Fuel) Generator Load The Generator Load Input (GLI) circuit is used by the PCM to determine generator load on the engine. As generator load increases the PCM will adjust idle speed accordingly. This strategy helps reduce idle surges due to switching high current loads. The GLI signal is sent to the PCM from the voltage regulator/generator. The signal is a variable frequency duty cycle. Normal operating frequency is 40 - 250 Hz. Normal signal DC voltage (referenced to ground) is between 1.5 V (low generator load) and 10.5 V (high generator load). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Description and Operation > Standard Models (Non BI-Fuel) > Page 6541 Generator: Description and Operation The generator system consists of: ^ generator ^ battery ^ wiring harness Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Testing and Inspection > Additional Diagnosis Generator: Testing and Inspection Additional Diagnosis For further information regarding the diagnosis of this component, please refer to Charging System; Testing and Inspection. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Testing and Inspection > Additional Diagnosis > Page 6544 Generator: Testing and Inspection Generator Testing CAUTION: ^ To prevent damage to the generator, do not make the jumper wire connections except as directed. ^ Do not allow any metal object to come in contact with the housing and the internal diode cooling fins with key on or off. A short circuit will result and burn out the diodes. NOTE: ^ Battery posts and cable clamps must be clean and tight for accurate meter indications. ^ Refer to the battery tester manual for complete directions for testing the charging system. 1. Turn off all lamps and electrical components. 2. Place the transmission range selector lever in NEUTRAL and apply the parking brake. 3. Carry out the Load Test and No-Load Test according to the following component tests: Generator-On Vehicle Tests - Load Test 1. Switch the battery tester to the ammeter function. 2. Connect the positive and negative leads of the battery tester to the corresponding battery terminals. 3. Connect the current probe to the generator B+ output terminal, circuit 38 (BK/OG). 4. With the engine running, turn the A/C on, the blower motor on high speed and the headlamps on high beam. 5. Increase the engine speed to approximately 2,000 rpm. The voltage should increase a minimum of 0.5 volt above the base voltage. ^ If the voltage does not increase as specified, carry out the Generator On-Vehicle Tests. ^ If the voltage increases as specified, the charging system is operating normally. 6. With the engine running at 2,000 rpm, adjust the tester load bank to determine the output of the generator. Generator output should be at least 58 amps. Generator-On Vehicle Tests - No-Load Test 1. Switch the battery tester to the voltmeter function. 2. Connect the voltmeter positive lead to the generator B+ output terminal, circuit 38 (BK/OG) and the negative lead to ground. 3. Turn all electrical accessories off. 4. With the engine running at 2,000 rpm, check the generator output voltage. The voltage should be between 13.0 and 15.0 volts. If not, refer to the Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Testing and Inspection > Page 6545 Generator: Service and Repair REMOVAL 1. Disconnect the battery. 2. Remove the air cleaner outlet tube. 3. Remove the drive belt. 4. Disconnect the wiring harness to voltage regulator electrical connector. 5. Remove the B+ terminal cover. 6. Remove the B+ terminal electrical connector. 1 Remove the B+ terminal nut. 2 Disconnect the B+ terminal electrical connector. 7. Remove the wiring harness-to-generator pin-type retainer. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Testing and Inspection > Page 6546 8. Remove the generator. 1 Remove the stud bolts and nut. 2 Remove the generator. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Diagrams Connector View C257 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Specifications Ignition Switch Lock Cylinder: Specifications Lock Cylinder Housing Screws ............................................................................................................ .................................................... 22 Nm (16 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder-Functional Lock Cylinder Removal 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock cylinder. 3. To install, reverse the removal procedure. ^ Verify ignition switch lock cylinder operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 6557 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional Ignition Switch Lock Cylinder-Non-Functional Lock Cylinder Removal and Installation 1. NOTE: Make sure the front wheels are in the straight-ahead position. Disconnect the battery ground cable and wait at least one minute. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes and instructions in the steering wheel removal and installation procedure. Remove the steering wheel assembly. 3. Twist off the cap from the ignition switch cylinder. 4. NOTE: The lock cylinder is repaired by discarding the inoperative lock cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code oil the vehicle. Remove the ignition switch lock cylinder. ^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. ^ Use a 3/8-inch drill bit to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. ^ Remove and discard the ignition switch lock cylinder and clean the drill shavings from the steering column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 6558 5. Remove the bearing retainer. 6. Remove the bearing and gear. ^ Thoroughly clean all drill shavings from the steering column and inspect it for damage. 7. To install, reverse the removal procedure. ^ Install a new ignition switch lock cylinder. ^ Verify ignition switch lock cylinder operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Starting System > Digital Transmission Range Sensor <--> [Neutral Safety Switch] > Component Information > Locations View 151-5 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Starting System > Digital Transmission Range Sensor <--> [Neutral Safety Switch] > Component Information > Locations > Page 6562 Connector View C167 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Starting System > Digital Transmission Range Sensor <--> [Neutral Safety Switch] > Component Information > Locations > Page 6563 Digital Transmission Range Sensor: Description and Operation Digital Transmission Range (TR) Sensor The digital Transmission Range (TR) sensor is located on the outside of the transmission at the manual lever. The digital TR sensor completes the start circuit in PARK, NEUTRAL, and the back-up lamp circuit in REVERSE. The digital TR sensor also opens and closes a set of four switches that are monitored by the Powertrain Control Module (PCM) to determine the position of the manual lever (P, R, N, (D), 3, 2, 1). See: Powertrain Management/Computers and Control Systems/Sensors and Switches - Computers and Control Systems/Digital Transmission Range Sensor Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Drive/Bendix > Component Information > Testing and Inspection Starter Drive/Bendix: Testing and Inspection Starter Drive and Flywheel Ring Gear Inspection 1. Remove the starter motor. 2. Check the wear patterns on the starter drive gear and the flywheel ring gear. If the wear pattern is abnormal, install a new starter motor, refer to Starter Motor. 3. If the starter drive gear and the flywheel ring gear are not fully meshing and both of the gears are scored or damaged, install a new starter motor, refer to Starter Motor. If necessary, install a new flywheel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Starter Relay: Locations Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 6571 Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 6572 Connector View C1017 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 6573 Starter Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 6574 Relay - Micro ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Point <--> [Auxiliary Power Outlet] > Component Information > Diagrams > Power Point, Console Connector View C380 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Point <--> [Auxiliary Power Outlet] > Component Information > Diagrams > Power Point, Console > Page 6580 Connector View C474 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Point <--> [Auxiliary Power Outlet] > Component Information > Diagrams > Power Point, Console > Page 6581 Connector View C2033 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box View 151-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box > Page 6586 View 151-9 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Page 6587 Connector View C1035 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6596 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6597 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6598 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6599 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6600 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6601 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6602 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6603 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6609 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6610 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6611 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6612 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6613 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6614 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6615 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6616 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Page 6617 Connector View C174 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6622 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6623 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6624 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6625 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6626 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6627 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6628 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6629 Fuse: Locations Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6630 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6631 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6632 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6633 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6634 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6635 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6636 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6637 Fuse: Locations Auxiliary Relay Box 1 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6638 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6639 Fuse: Locations Auxiliary Relay Box 2 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6640 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. NOTE: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6643 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number or the component name in one of the the A-Z Component Lists, the Component Location description for that component can easily be found. See: Locations/Component Locations/A-Z Component List Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6644 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6645 the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6646 that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6647 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6648 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6649 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6650 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6651 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6652 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6653 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6654 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6655 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6656 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6657 Systems Overview Wire Color Code Identification Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6658 OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6659 Fuse: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6660 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6661 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6664 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6665 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6666 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6667 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6668 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6669 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6670 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6671 Fuse: Application and ID Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6672 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6673 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6674 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6675 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6676 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6677 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6678 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6679 Fuse: Application and ID Auxiliary Relay Box 1 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6680 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6681 Fuse: Application and ID Auxiliary Relay Box 2 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6682 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse Block: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6687 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6688 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6689 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6690 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6691 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6692 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6693 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6694 Fuse Block: Locations Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6695 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6696 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6697 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6698 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6699 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6700 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6701 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6702 Fuse Block: Locations Auxiliary Relay Box 1 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6703 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6704 Fuse Block: Locations Auxiliary Relay Box 2 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6705 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. NOTE: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6708 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number or the component name in one of the the A-Z Component Lists, the Component Location description for that component can easily be found. See: Locations/Component Locations/A-Z Component List Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6709 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6710 the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6711 that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6712 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6713 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6714 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6715 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6716 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6717 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6718 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6719 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6720 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6721 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6722 Systems Overview Wire Color Code Identification Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6723 OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6724 Fuse Block: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6725 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6726 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse Block: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6729 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6730 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6731 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6732 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6733 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6734 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6735 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6736 Fuse Block: Application and ID Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6737 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6738 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6739 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6740 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6741 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6742 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6743 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6744 Fuse Block: Application and ID Auxiliary Relay Box 1 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6745 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6746 Fuse Block: Application and ID Auxiliary Relay Box 2 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6747 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 6751 Relay - Micro ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 6755 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C264 Multiple Junction Connector: Diagrams C110 - C264 Connector View C110 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C264 > Page 6760 Connector View C126 Connector View C139 Connector View C144 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C264 > Page 6761 Connector View C146 Connector View C210 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C264 > Page 6762 Connector View C211 Connector View C212 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C264 > Page 6763 Connector View C213 Connector View C214 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C264 > Page 6764 Connector View C215 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C264 > Page 6765 Connector View C219 Connector View C237 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C264 > Page 6766 Connector View C238 Connector View C263 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C264 > Page 6767 Connector View C264 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C264 > Page 6768 Multiple Junction Connector: Diagrams C311 - C510 Connector View C311 Connector View C312 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C264 > Page 6769 Connector View C313 Connector View C314 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C264 > Page 6770 Connector View C316 Connector View C327 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C264 > Page 6771 Connector View C328 Connector View C339 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C264 > Page 6772 Connector View C340 Connector View C406 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C264 > Page 6773 Connector View C408 Connector View C410 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C264 > Page 6774 Connector View C411 Connector View C421 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C264 > Page 6775 Connector View C422 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C264 > Page 6776 Connector View C510 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C264 > Page 6777 Multiple Junction Connector: Diagrams C919 - C3007 Connector View C919 Connector View C922 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C264 > Page 6778 Connector View C295 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C264 > Page 6779 Connector View C3007 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Power Distribution Relay: Locations Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 6783 Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 6784 Connector View C2049 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 6785 Power Distribution Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 6786 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Protection Relay > Component Information > Locations > Auxiliary Relay Box 2 Relay ID - Before 2/18/02 Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Protection Relay > Component Information > Locations > Auxiliary Relay Box 2 Relay ID - Before 2/18/02 > Page 6791 Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 6796 Relay - Micro ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 6800 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Power Distribution Relay: Locations Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 6804 Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 6805 Connector View C2049 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 6806 Power Distribution Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 6807 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Protection Relay > Component Information > Locations > Auxiliary Relay Box 2 Relay ID Before 2/18/02 Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Protection Relay > Component Information > Locations > Auxiliary Relay Box 2 Relay ID Before 2/18/02 > Page 6812 Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6817 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6818 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6819 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6820 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6821 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6822 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6823 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6824 Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6825 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6826 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6827 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6828 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6829 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6830 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6831 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6832 Relay Box: Locations Auxiliary Relay Box 1 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6833 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6834 Relay Box: Locations Auxiliary Relay Box 2 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6835 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6838 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6839 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6840 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6841 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6842 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6843 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6844 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6845 Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6846 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6847 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6848 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6849 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6850 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6851 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6852 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6853 Relay Box: Application and ID Auxiliary Relay Box 1 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6854 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6855 Relay Box: Application and ID Auxiliary Relay Box 2 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6856 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6861 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6862 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6863 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6864 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6865 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6866 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6867 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6868 Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6869 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6870 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6871 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6872 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6873 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6874 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6875 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6876 Relay Box: Locations Auxiliary Relay Box 1 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6877 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6878 Relay Box: Locations Auxiliary Relay Box 2 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6879 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6882 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6883 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6884 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6885 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6886 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6887 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6888 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6889 Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6890 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6891 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6892 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6893 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6894 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6895 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6896 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6897 Relay Box: Application and ID Auxiliary Relay Box 1 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6898 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6899 Relay Box: Application and ID Auxiliary Relay Box 2 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6900 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips Technical Service Bulletin # 05-18-7 Date: 050922 Electrical - Wiring Soldering/Crimping Service Tips TSB 05-18-7 09/22/05 WIRING - SOLDERING AND CRIMPING REPAIRS - SERVICE TIPS FORD: 2000-2006 Crown Victoria, Focus, Mustang, Taurus 2002-2005 Thunderbird 2005-2006 Five Hundred, Ford GT, Freestyle 2006 Fusion 2000-2003 Explorer Sport, Windstar 2000-2005 Excursion 2000-2006 E-Series, Expedition, Explorer, F-150, F-Super Duty, Ranger 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape Hybrid 2000-2006 F-650, F-750 2006 Low Cab Forward LINCOLN: 2000-2006 LS, Town Car 2006 Zephyr 2000-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006 Mark LT MERCURY: 2000-2002 Cougar 2000-2005 Sable 2000-2006 Grand Marquis 2005-2006 Montego 2006 Milan 2000-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner 2006 Mariner Hybrid This article supersedes TSB 03-11-6 to update the service procedure, vehicle lines and model years. ISSUE Wire harness repairs are supported through the availability of individual components such as: ^ Wire terminals with machine crimped pigtails ^ Hard shell connectors ^ Dual wall heat shrink tubing ^ Complete, loaded, wiring pigtail kits Some of the available tools and service parts that are helpful when performing wiring harness repairs are: ^ Motorcraft Wiring Pigtail Catalog (see website for more information) ^ Rotunda Wire Splice Tool kit 164-R5903 ^ General Wire Terminal Repair Kit (order through Ford Component Sales) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 6905 Information on the pigtail and terminal repair kits can also be accessed by technicians via the P15 web site. To access on PTS: ^ Select the year/model of the vehicle on the P15 home page ^ Select the wiring tab ^ Select the link to the pigtail or terminal repair kit at the top right of screen. Additional service information contained in this TSB detailing wire folding, soldering, and crimping techniques may be helpful. ACTION REPAIR VS REPLACEMENT The approved procedure is to repair wiring harnesses with pigtail kits, wire terminals, or hard shell connectors when available. The only exceptions to this procedure are when: ^ The repair cost exceeds the cost to replace the wiring harness ^ There are no component parts released to service the wiring harness RESTRAINTS RELATED WIRING REPAIRS If restraints connectors or wiring circuits are contained in a stand-alone harness, do not repair them; replace the restraints harness unless directed to repair the circuit by a TSB or other Ford Motor Company publication. If restraints connectors or wiring circuits are contained in the main vehicle wiring harnesses (14401, 14A005, etc.), they should be repaired using the solder and heat-shrink repair procedure specified in this TSB. The General Wire Terminal Repair Kit contains gold plated terminated pigtails (with white insulation) and dual wall heat shrink tubing to perform these repairs. Loaded wiring pigtail kits with gold plated terminals are also available in the parts catalog. Disclaimer Service Tips Refer to applicable model year wiring diagrams for circuit information. Twisted Wire Circuits For "Twisted Wire" circuit repair (Figure 1), the twisting must not be disrupted for more than 2" (51 mm) Twist the repaired wires in the same direction and with the same general twist rate as the original wiring. Reapply the shielding on shielded circuits. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 6906 Stagger the repairs to minimize harness diameter and maintain harness length (Figure 2). Any leads that are not going to be used need to be sealed with dual wall heat shrink and stowed (Figure 2). Silicone must not be used. Excess wire from the harness can be folded back on itself to maintain the harness length. Reapply any convolute and tape that was removed to make the repair. For 16 AGW and Smaller Diameter Wire Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 6907 1. Strip 1-1/2" (37.2 mm) of insulation from Wire # 1 and 3/4" (19.5 mm) of insulation from Wire # 2, taking care not to nick or cut wire strands (Figure 3). Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut off the end and re-strip. 2. Install heat shrink tubing at least 1" (26 mm) away from one of the stripped ends being spliced. Twist wires together. Solder wires together (Figure 4). NOTE USE ROSIN CORE MILDLY ACTIVATED (RMS) SOLDER. DO NOT USE ACID CORE SOLDER FOR WIRE REPAIR. 3. Bend Wire # 1 back in a straight line for sealing (Figure 4). Inspect solder joint bond. NOTE WAIT FOR SOLDER TO COOL BEFORE MOVING WIRES. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 6908 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 6909 4. Evenly position heat shrink tubing over wire repair (Figure 5). NOTE OVERLAP TUBING ON BOTH WIRES. 5. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the solder point (Figure 5). For 14 AGW and Larger Diameter Wire (Excluding Restraints Wiring Repairs) 1. Strip 1/4" (6.35 mm) of insulation from pigtail wire end once the wire lengths are sized so repairs can be staggered. Take care not to nick or cut wire strands. Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut off the end and re-strip. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 6910 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 6911 NOTE THE STRIP LENGTH WILL VARY DEPENDING ON THE BUTT SPLICE AND WIRE IN HARNESS. LONGER STRIP LENGTHS ARE REQUIRED WHEN THE WIRE NEEDS TO BE FOLDED TO MATE WITH THE BUTT SPLICE. REFER TO FIGURE 10 CHART FOR STRIP LENGTHS AND FOLDING TECHNIQUES. 2. Slide heat shrink tubing onto one (1) of the wire ends to be crimped, must be at least 1" (25.4 mm) away from stripped end (Figure 6). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 6912 3. Identify the appropriate crimping chamber of the Rotunda 164-R5901 Pro-Crimper (or equivalent) by matching the wire size on the dies with the wire size stamped on the butt splice (Figure 7). Hold the crimping tool so the identified wire sizes are facing you. Squeeze tool handles together until the ratchet releases, then allow the jaws of the tool to open fully. 4. Center one (1) end of the butt splice on the appropriate crimping chamber. If visible, be sure to place the brazed seam of the butt splice toward the indenter (Figure 8). 5. Hold the butt splice in place and squeeze the tool handles together until the ratchet engages sufficiently to hold the butt splice in position (typically one (1) or two (2) clicks). DO NOT deform the butt splice. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 6913 6. Insert stripped wire into the buff splice, making sure the insulation on wire does not enter the butt splice (Figure 8). 7. Holding the wire in place, squeeze tool handles together until ratchet releases. Allow tool handles to open, then remove crimped butt splice. 8. To crimp the other half of the splice, reposition the un-crimped wire barrel in the same crimping chamber, and repeat Steps 3-8. If splice cannot be turned for crimping the other half, turn the tool around. 9. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. It is acceptable for crimp to be slightly off center, but not off the end of the buff splice (Figure 9-a). b. Wire insulation does not enter butt splice. Wire is flush with or extends slightly beyond end of buff splice (Figure 9-b). c. Wire is visible through inspection hole of splices (Figure 9-c). 10. Evenly position heat shrink tubing over wire repair (Figure 5). NOTE OVERLAP TUBING ON BOTH WIRES. 11. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the solder point (Figure 5). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Power Point <--> [Auxiliary Power Outlet] > Component Information > Diagrams > Power Point, Console Connector View C380 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Power Point <--> [Auxiliary Power Outlet] > Component Information > Diagrams > Power Point, Console > Page 6919 Connector View C474 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Power Point <--> [Auxiliary Power Outlet] > Component Information > Diagrams > Power Point, Console > Page 6920 Connector View C2033 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box View 151-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box > Page 6925 View 151-9 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Page 6926 Connector View C1035 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6935 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6936 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6937 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6938 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6939 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6940 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6941 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6942 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6948 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6949 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6950 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6951 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6952 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6953 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6954 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6955 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Page 6956 Connector View C174 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6961 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6962 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6963 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6964 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6965 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6966 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6967 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6968 Fuse: Locations Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6969 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6970 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6971 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6972 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6973 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6974 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6975 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6976 Fuse: Locations Auxiliary Relay Box 1 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6977 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6978 Fuse: Locations Auxiliary Relay Box 2 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6979 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. NOTE: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6982 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number or the component name in one of the the A-Z Component Lists, the Component Location description for that component can easily be found. See: Locations/Component Locations/A-Z Component List Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6983 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6984 the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6985 that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6986 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6987 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6988 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6989 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6990 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6991 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6992 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6993 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6994 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6995 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6996 Systems Overview Wire Color Code Identification Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6997 OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6998 Fuse: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6999 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7003 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7004 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7005 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7006 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7007 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7008 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7009 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7010 Fuse: Application and ID Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7011 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7012 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7013 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7014 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7015 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7016 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7017 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7018 Fuse: Application and ID Auxiliary Relay Box 1 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7019 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7020 Fuse: Application and ID Auxiliary Relay Box 2 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7021 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse Block: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7026 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7027 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7028 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7029 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7030 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7031 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7032 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7033 Fuse Block: Locations Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7034 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7035 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7036 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7037 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7038 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7039 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7040 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7041 Fuse Block: Locations Auxiliary Relay Box 1 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7042 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7043 Fuse Block: Locations Auxiliary Relay Box 2 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7044 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. NOTE: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7047 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number or the component name in one of the the A-Z Component Lists, the Component Location description for that component can easily be found. See: Locations/Component Locations/A-Z Component List Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7048 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7049 the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7050 that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7051 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7052 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7053 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7054 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7055 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7056 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7057 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7058 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7059 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7060 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7061 Systems Overview Wire Color Code Identification Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7062 OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7063 Fuse Block: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7064 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7065 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse Block: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7068 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7069 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7070 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7071 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7072 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7073 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7074 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7075 Fuse Block: Application and ID Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7076 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7077 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7078 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7079 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7080 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7081 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7082 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7083 Fuse Block: Application and ID Auxiliary Relay Box 1 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7084 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7085 Fuse Block: Application and ID Auxiliary Relay Box 2 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7086 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 7090 Relay - Micro ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 7094 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C264 Multiple Junction Connector: Diagrams C110 - C264 Connector View C110 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C264 > Page 7099 Connector View C126 Connector View C139 Connector View C144 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C264 > Page 7100 Connector View C146 Connector View C210 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C264 > Page 7101 Connector View C211 Connector View C212 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C264 > Page 7102 Connector View C213 Connector View C214 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C264 > Page 7103 Connector View C215 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C264 > Page 7104 Connector View C219 Connector View C237 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C264 > Page 7105 Connector View C238 Connector View C263 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C264 > Page 7106 Connector View C264 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C264 > Page 7107 Multiple Junction Connector: Diagrams C311 - C510 Connector View C311 Connector View C312 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C264 > Page 7108 Connector View C313 Connector View C314 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C264 > Page 7109 Connector View C316 Connector View C327 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C264 > Page 7110 Connector View C328 Connector View C339 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C264 > Page 7111 Connector View C340 Connector View C406 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C264 > Page 7112 Connector View C408 Connector View C410 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C264 > Page 7113 Connector View C411 Connector View C421 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C264 > Page 7114 Connector View C422 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C264 > Page 7115 Connector View C510 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C264 > Page 7116 Multiple Junction Connector: Diagrams C919 - C3007 Connector View C919 Connector View C922 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C264 > Page 7117 Connector View C295 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110 - C264 > Page 7118 Connector View C3007 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Power Distribution Relay: Locations Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 7122 Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 7123 Connector View C2049 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 7124 Power Distribution Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 7125 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Power Protection Relay > Component Information > Locations > Auxiliary Relay Box 2 Relay ID - Before 2/18/02 Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Power Protection Relay > Component Information > Locations > Auxiliary Relay Box 2 Relay ID - Before 2/18/02 > Page 7130 Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 7135 Relay - Micro ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 7139 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Power Distribution Relay: Locations Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 7143 Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 7144 Connector View C2049 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 7145 Power Distribution Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 7146 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Protection Relay > Component Information > Locations > Auxiliary Relay Box 2 Relay ID - Before 2/18/02 Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Protection Relay > Component Information > Locations > Auxiliary Relay Box 2 Relay ID - Before 2/18/02 > Page 7151 Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7156 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7157 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7158 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7159 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7160 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7161 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7162 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7163 Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7164 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7165 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7166 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7167 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7168 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7169 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7170 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7171 Relay Box: Locations Auxiliary Relay Box 1 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7172 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7173 Relay Box: Locations Auxiliary Relay Box 2 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7174 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7177 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7178 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7179 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7180 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7181 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7182 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7183 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7184 Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7185 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7186 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7187 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7188 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7189 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7190 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7191 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7192 Relay Box: Application and ID Auxiliary Relay Box 1 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7193 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7194 Relay Box: Application and ID Auxiliary Relay Box 2 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7195 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7200 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7201 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7202 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7203 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7204 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7205 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7206 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7207 Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7208 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7209 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7210 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7211 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7212 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7213 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7214 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7215 Relay Box: Locations Auxiliary Relay Box 1 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7216 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7217 Relay Box: Locations Auxiliary Relay Box 2 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7218 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7221 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7222 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7223 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7224 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7225 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7226 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7227 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7228 Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7229 Sport, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7230 Sport Trac, Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7231 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7232 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7233 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7234 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7235 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7236 Relay Box: Application and ID Auxiliary Relay Box 1 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7237 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7238 Relay Box: Application and ID Auxiliary Relay Box 2 Before 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7239 As Of 2/18/02 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips Technical Service Bulletin # 05-18-7 Date: 050922 Electrical - Wiring Soldering/Crimping Service Tips TSB 05-18-7 09/22/05 WIRING - SOLDERING AND CRIMPING REPAIRS - SERVICE TIPS FORD: 2000-2006 Crown Victoria, Focus, Mustang, Taurus 2002-2005 Thunderbird 2005-2006 Five Hundred, Ford GT, Freestyle 2006 Fusion 2000-2003 Explorer Sport, Windstar 2000-2005 Excursion 2000-2006 E-Series, Expedition, Explorer, F-150, F-Super Duty, Ranger 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape Hybrid 2000-2006 F-650, F-750 2006 Low Cab Forward LINCOLN: 2000-2006 LS, Town Car 2006 Zephyr 2000-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006 Mark LT MERCURY: 2000-2002 Cougar 2000-2005 Sable 2000-2006 Grand Marquis 2005-2006 Montego 2006 Milan 2000-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner 2006 Mariner Hybrid This article supersedes TSB 03-11-6 to update the service procedure, vehicle lines and model years. ISSUE Wire harness repairs are supported through the availability of individual components such as: ^ Wire terminals with machine crimped pigtails ^ Hard shell connectors ^ Dual wall heat shrink tubing ^ Complete, loaded, wiring pigtail kits Some of the available tools and service parts that are helpful when performing wiring harness repairs are: ^ Motorcraft Wiring Pigtail Catalog (see website for more information) ^ Rotunda Wire Splice Tool kit 164-R5903 ^ General Wire Terminal Repair Kit (order through Ford Component Sales) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7244 Information on the pigtail and terminal repair kits can also be accessed by technicians via the P15 web site. To access on PTS: ^ Select the year/model of the vehicle on the P15 home page ^ Select the wiring tab ^ Select the link to the pigtail or terminal repair kit at the top right of screen. Additional service information contained in this TSB detailing wire folding, soldering, and crimping techniques may be helpful. ACTION REPAIR VS REPLACEMENT The approved procedure is to repair wiring harnesses with pigtail kits, wire terminals, or hard shell connectors when available. The only exceptions to this procedure are when: ^ The repair cost exceeds the cost to replace the wiring harness ^ There are no component parts released to service the wiring harness RESTRAINTS RELATED WIRING REPAIRS If restraints connectors or wiring circuits are contained in a stand-alone harness, do not repair them; replace the restraints harness unless directed to repair the circuit by a TSB or other Ford Motor Company publication. If restraints connectors or wiring circuits are contained in the main vehicle wiring harnesses (14401, 14A005, etc.), they should be repaired using the solder and heat-shrink repair procedure specified in this TSB. The General Wire Terminal Repair Kit contains gold plated terminated pigtails (with white insulation) and dual wall heat shrink tubing to perform these repairs. Loaded wiring pigtail kits with gold plated terminals are also available in the parts catalog. Disclaimer Service Tips Refer to applicable model year wiring diagrams for circuit information. Twisted Wire Circuits For "Twisted Wire" circuit repair (Figure 1), the twisting must not be disrupted for more than 2" (51 mm) Twist the repaired wires in the same direction and with the same general twist rate as the original wiring. Reapply the shielding on shielded circuits. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7245 Stagger the repairs to minimize harness diameter and maintain harness length (Figure 2). Any leads that are not going to be used need to be sealed with dual wall heat shrink and stowed (Figure 2). Silicone must not be used. Excess wire from the harness can be folded back on itself to maintain the harness length. Reapply any convolute and tape that was removed to make the repair. For 16 AGW and Smaller Diameter Wire Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7246 1. Strip 1-1/2" (37.2 mm) of insulation from Wire # 1 and 3/4" (19.5 mm) of insulation from Wire # 2, taking care not to nick or cut wire strands (Figure 3). Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut off the end and re-strip. 2. Install heat shrink tubing at least 1" (26 mm) away from one of the stripped ends being spliced. Twist wires together. Solder wires together (Figure 4). NOTE USE ROSIN CORE MILDLY ACTIVATED (RMS) SOLDER. DO NOT USE ACID CORE SOLDER FOR WIRE REPAIR. 3. Bend Wire # 1 back in a straight line for sealing (Figure 4). Inspect solder joint bond. NOTE WAIT FOR SOLDER TO COOL BEFORE MOVING WIRES. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7247 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7248 4. Evenly position heat shrink tubing over wire repair (Figure 5). NOTE OVERLAP TUBING ON BOTH WIRES. 5. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the solder point (Figure 5). For 14 AGW and Larger Diameter Wire (Excluding Restraints Wiring Repairs) 1. Strip 1/4" (6.35 mm) of insulation from pigtail wire end once the wire lengths are sized so repairs can be staggered. Take care not to nick or cut wire strands. Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut off the end and re-strip. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7249 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7250 NOTE THE STRIP LENGTH WILL VARY DEPENDING ON THE BUTT SPLICE AND WIRE IN HARNESS. LONGER STRIP LENGTHS ARE REQUIRED WHEN THE WIRE NEEDS TO BE FOLDED TO MATE WITH THE BUTT SPLICE. REFER TO FIGURE 10 CHART FOR STRIP LENGTHS AND FOLDING TECHNIQUES. 2. Slide heat shrink tubing onto one (1) of the wire ends to be crimped, must be at least 1" (25.4 mm) away from stripped end (Figure 6). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7251 3. Identify the appropriate crimping chamber of the Rotunda 164-R5901 Pro-Crimper (or equivalent) by matching the wire size on the dies with the wire size stamped on the butt splice (Figure 7). Hold the crimping tool so the identified wire sizes are facing you. Squeeze tool handles together until the ratchet releases, then allow the jaws of the tool to open fully. 4. Center one (1) end of the butt splice on the appropriate crimping chamber. If visible, be sure to place the brazed seam of the butt splice toward the indenter (Figure 8). 5. Hold the butt splice in place and squeeze the tool handles together until the ratchet engages sufficiently to hold the butt splice in position (typically one (1) or two (2) clicks). DO NOT deform the butt splice. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7252 6. Insert stripped wire into the buff splice, making sure the insulation on wire does not enter the butt splice (Figure 8). 7. Holding the wire in place, squeeze tool handles together until ratchet releases. Allow tool handles to open, then remove crimped butt splice. 8. To crimp the other half of the splice, reposition the un-crimped wire barrel in the same crimping chamber, and repeat Steps 3-8. If splice cannot be turned for crimping the other half, turn the tool around. 9. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. It is acceptable for crimp to be slightly off center, but not off the end of the buff splice (Figure 9-a). b. Wire insulation does not enter butt splice. Wire is flush with or extends slightly beyond end of buff splice (Figure 9-b). c. Wire is visible through inspection hole of splices (Figure 9-c). 10. Evenly position heat shrink tubing over wire repair (Figure 5). NOTE OVERLAP TUBING ON BOTH WIRES. 11. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the solder point (Figure 5). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Alignment Procedure Revision Alignment: Technical Service Bulletins Steering/Suspension - Alignment Procedure Revision TSB 04-24-19 12/13/04 REVISED PROCEDURE FOR ADJUSTING ALIGNMENT ON ALL SUSPENSIONS - NEW RIGHT HAND UPPER CONTROL ARM DESIGN FOR TORSION BAR FRONT SUSPENSIONS FORD: 1998-2001 Explorer 1998-2003 Ranger 2000-2003 Explorer Sport 2001-2003 Explorer Sport Trac ISSUE The cam bolt and nut kit that was used for adjusting caster and camber on all torsion bar and coil spring front suspensions has been discontinued. If the caster and camber settings need to be adjusted, a washer must now be installed. The right hand upper control arm design changed from a two piece design to a single piece design during the 2003 model year. The single piece design is now the only version of the upper control arm available for service of prior model year Rangers. ACTION Use the following Camber And Caster Adjustment procedure when either camber or caster need to be adjusted on any suspension, or if only a caster split adjustment is needed on a vehicle equipped with single piece upper control arm. Use the following Caster Split Adjustment - Two Piece Right Hand Upper Control Arm procedure if only a caster split adjustment is needed on a vehicle equipped with a two piece upper control arm. SERVICE PROCEDURE CAMBER AND CASTER ADJUSTMENT NOTE THE UPPER CONTROL ARM-TO-FRAME MOUNTING BOLTS HAVE SET SHIMS THAT MUST BE REPLACED WITH WASHERS TO ALLOW FOR ADJUSTMENT OF THE ARM IN THE FRAME SLOT. THE VEHICLE SHOULD BE SUPPORTED BY THE LOWER CONTROL ARM TO EASE MOVEMENT OF THE UPPER ARM IN THE SLOT. 1. Remove and discard the upper control arm-to-frame nuts and shims (Figure 1). 2. Install new washers (W705040-5900) and nuts (N805480-5427). Tighten the nuts so there is tension, but the upper control arm can be moved for the alignment adjustment. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Alignment Procedure Revision > Page 7258 3. To adjust caster and camber refer to the chart. Adjustments that require moving the front and rear of the upper control arm should be made equally. 4. Torque the upper control arm-to-frame nuts to 98 lb.ft (133 N.m). 5. Check and if necessary adjust the front toe. Refer to the appropriate Workshop Manual for information. CASTER SPLIT ADJUSTMENT - TWO PIECE RIGHT HAND UPPER CONTROL ARM 1. To decrease the right hand caster, loosen the ball joint adjustment nuts (Figure 2) and move the ball joint forward. 2. To increase the right hand caster, loosen the ball joint adjustment nuts and move the ball joint rearward. 3. Torque the ball joint adjustment nuts to 129 lb.ft (175 N.m). 4. Check and if necessary adjust the front toe. Refer to the appropriate Workshop Manual for information. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 3084 07 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 7259 Alignment: Specifications Alignment Specifications Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 7260 General Specifications Torque Specifications Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 7261 Alignment: Description and Operation Wheel Alignment Angles Caster and camber are adjusted by means of eccentric cams on the upper control arm mounting bolts. Toe is adjusted by the use of the front wheel spindle tie-rod. Camber Negative and Positive Camber Negative and Positive Camber Camber is the vertical tilt of the wheel when viewed from the front. Camber can be positive or negative and has a direct effect on tire wear. Caster Caster is the deviation from vertical of an imaginary line drawn through the ball joints when viewed from the side. The caster specifications will give the vehicle the best directional stability characteristics when loaded and driven. The caster setting is not related to tire wear. Toe Positive Toe (Toe In) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 7262 Positive Toe (Toe In) Negative Toe (Toe Out) Negative Toe (Toe Out) The vehicle toe setting: ^ affects tire wear and directional stability. ^ must be checked after adding aftermarket equipment, such as a snowplow or body. Ride Height Front Ride Height Measurement Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 7263 Rear Ride Height Measurement Wheel Track Wheel Track Dogtracking Dogtracking Dogtracking is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can give the illusion of dogtracking. Wander Wander is the tendency of the vehicle to require frequent, random left and right steering wheel corrections to maintain a straight path down a level road. Shimmy Shimmy, as observed by the driver, is large, consistent, rotational oscillations of the steering wheel resulting from large, side-to-side (lateral) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 7264 tire/wheel movements. Shimmy is usually experienced near 64 km/h (40 mph), and can begin or be amplified when the tire contacts pot holes or irregularities in the road surface. Nibble Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with various road surfaces and observed by the driver as small rotational oscillations of the steering wheel. Poor Returnability/Sticky Steering Poor returnability and sticky steering is used to describe the poor return of the steering wheel to center after a turn or the steering correction is completed. Drift/Pull Pull is a tugging sensation, felt by the hands on the steering wheel, that must be overcome to keep the vehicle going straight. Drift describes what a vehicle with this condition does with hands off the steering wheel. ^ A vehicle-related drift/pull, on a flat road, will cause a consistent deviation from the straight-ahead path and require constant steering input in the opposite direction to counteract the effect. ^ Drift/pull may be induced by conditions external to the vehicle (i.e., wind, road camber). Poor Groove Feel Poor groove feel is characterized by little or no buildup of turning effort felt in the steering wheel as the wheel is rocked slowly left and right within very small turns around center or straight-ahead (under 20 degrees of steering wheel turn). Efforts may be said to be "flat on center." ^ Under 20 degrees of turn, most of the turning effort that builds up comes from the mesh of gear teeth in the steering gear. In this range, the steering wheel is not yet turned enough to feel the effort from the self-aligning forces at the road wheel or tire patch. ^ In the diagnosis of a readability problem, it is important to understand the difference between wander and poor groove feel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment Alignment: Service and Repair Camber and Caster Adjustment Camber and Caster Adjustment 1. Remove the nuts and alignment plates. 2. Install the cams and the nuts. 3. NOTE: A pry bar can be used between the front suspension arm bushing joint and the frame pocket to aid in moving the arm. To increase the LF caster and camber, use the following steps. 1 To increase caster, move the front of the front suspension arm bushing joint outboard and move the rear of the front suspension arm bushing joint inboard. 2 To increase camber, move the front suspension arm bushing joint outboard equally. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 7267 4. To decrease the LF caster and camber, use the following steps. 1 To decrease caster, move the front of the front suspension arm bushing joint inboard and move the rear of the front suspension arm bushing joint outboard. 2 To decrease camber, move the front suspension arm bushing joint inboard equally. 5. Tighten the nuts. 6. NOTE: A pry bar can be used between the front suspension arm bushing joint and the frame pocket to aid in moving the arm. To increase RF caster and camber, use the following steps. 1 To increase-caster, move the front of the front suspension arm bushing joint outboard and move the rear of the front suspension arm bushing joint inboard. 2 To increase camber, move the front suspension arm bushing joint outboard equally. 7. To decrease the RF caster and camber, use the following steps. 1 To decrease caster, move the front of the front suspension arm bushing joint inboard and move the rear of the front suspension arm bushing joint outboard. 2 To decrease camber, move the front suspension arm bushing joint inboard equally. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 7268 8. Increase the caster split. 1 Loosen the nuts. 2 Adjust the caster set bolts forward. 9. Decrease the caster split. 1 Loosen the nuts. 2 Adjust the caster set bolts rearward. 10. Tighten the nuts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 7269 Alignment: Service and Repair Toe Adjustment Toe Adjustment 1. Start the engine and center the steering wheel. 2. Turn the engine off, and hold the steering wheel in the "straight forward" position by attaching a rigid link from the steering wheel to the brake pedal. 3. Check the toe settings; follow the manufacturer's instructions. 4. NOTE: Do not allow the steering gear bellows to twist when the front wheel spindle tie-rod is rotated. Remove the clamps. 5. Loosen the nuts. ^ Clean and lubricate the nut(s) and front wheel spindle tie-rod threads. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 7270 6. Rotate the front wheel spindle tie-rods. 7. Tighten the nuts. 8. Install the clamps. 9. Recheck the toe settings; follow the manufacturer's instructions. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Specifications Steering Angle Sensor: Specifications Steering Wheel Rotation Sensor Bolts .................................................................................................................................................... 1 Nm (10 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Specifications > Page 7276 Steering Angle Sensor: Service and Repair "For information regarding this component please refer to steering column service and repair" Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Specifications Steering Angle Sensor: Specifications Steering Wheel Rotation Sensor Bolts .................................................................................................................................................... 1 Nm (10 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Specifications > Page 7281 Steering Angle Sensor: Service and Repair "For information regarding this component please refer to steering column service and repair" Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage Power Steering Fluid: Technical Service Bulletins Steering - Mercon V(R) Fluid Usage TSB 07-1-7 01/22/07 MERCON(R) ATF REPLACED BY MERCON(R) V AS A SERVICE FLUID FOR SOME POWER STEERING SYSTEMS FORD: 1996-1997 Thunderbird 1996-2007 Crown Victoria, Mustang, Taurus 1998-2003 Escort 2000-2007 Focus 2002-2005 Thunderbird 2005-2006 Ford GT 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1996-1997 Aerostar 1996-2007 E-Series, Explorer, Ranger 1997-2004 F-53 Motorhome Chassis 1997-2007 Expedition, F-150, F-Super Duty 1998-2003 Windstar 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2007 Escape 2004-2007 Freestar 2005-2007 Escape Hybrid 1996-1997 Cargo 1996-1998 L-Series 1996-1999 F- B-Series 2000-2007 F-650, F-750 2006-2007 Low Cab Forward LINCOLN: 1996-1998 Mark VIII 1996-1999 Continental 1996-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX MERCURY: 1996-1997 Cougar 1996-2005 Sable 1996-2007 Grand Marquis 1999-2002 Cougar 2003-2004 Marauder 2005-2007 Montego 2006-2007 Milan 1997-2007 Mountaineer 1998-2002 Villager 2004-2007 Monterey 2005-2007 Mariner Hybrid, Mariner ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid for power steering systems originally requiring MERCON(R). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage > Page 7288 ACTION Beginning immediately all power steering applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will continue until remaining inventory has been depleted. SERVICE PROCEDURE Service power steering Systems requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. CAUTION APPLICATIONS RECOMMENDING TYPE F AUTOMATIC TRANSMISSION AND POWER STEERING FLUID MUST CONTINUE TO USE THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 7289 Power Steering Fluid: Specifications MERCON Multi-Purpose (ATF) Transmission Fluid XT-2-QDX MERCON or equivalent meeting Ford Specification MERCON. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Cooler: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns Power Steering Fluid Cooler: Customer Interest Steering - Shudder on Low Speed Turns TSB 05-17-15 09/05/05 STEERING SHUDDER DURING LOW SPEED MANEUVERS - 4.0L ENGINE FORD: 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac This article supersedes TSB 04-2-7 to update the vehicle model years and service procedure. ISSUE Some 2001-2005 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction between the tire and the road surface, which is amplified through the steering system. The condition will vary according to ambient temperature, road surface friction, and steering wheel turning speed. ACTION As design changes have taken place in the steering system, it is important to note the VEHICLE BUILD DATE and follow the appropriate steps outlined in the following Service Procedure. Perform a thorough evacuation of air from the power steering system after replacement/installation of parts. SERVICE PROCEDURE NOTE BEFORE REPLACING ANY COMPONENT, BE SURE TO CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. NOTE THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED OF AIR WITH A VACUUM AT THE RESERVOIR. FILL AND PURGE THE P/S SYSTEM FOLLOWING THE PROCEDURES CALLED OUT IN THE ON-LINE WORKSHOP MANUAL, SECTION 211-00. FOLLOWING THE EVACUATION PROCEDURE WILL REDUCE THE AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER. NOTE PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED. VEHICLES BUILT PRIOR TO APRIL 18, 2001 1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer to Workshop Manual, Section 211-02. 2. Replace the cooler assembly with service part F77Z-3D746-GA. Do not remove the existing cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the new return line from the new cooler and connect the new cooler fin pack to the existing return line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid loss from the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Cooler: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7298 4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figures 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section 211-00. 6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release B28.5 or higher. Calibration files may also be obtained at the website. VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001 NOTE FOR ALL 4X2 SPORT TRAC VEHICLES BUILT AFTER 4/18/2001, PROCEED DIRECTLY TO STEP 2. THESE VEHICLES ARE ALREADY EQUIPPED WITH THE HIGH OUTPUT DISPLACEMENT PUMP (5L2Z-3A674-CA). 1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer to the Workshop Manual, Section 211-02. 2. Replace the cooler assembly with service part (F77Z-3D746-GA). Do not remove the existing cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the new return line from the new cooler and connect the new cooler fin pack to the existing return line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid loss from the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Cooler: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7299 4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section 211-00. 6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release B28.5 or higher. Calibration files may also be obtained at the website. VEHICLES BUILT AFTER NOVEMBER 7, 2001 1. Remove the power steering cooler (Figure 3) from the steering gear. 2. Remove the return line from the power steering reservoir bottle (Figure 4). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Cooler: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7300 3. Remove the return line from the steering gear (Figure 5). 4. Replace the current cooler (3D746) and two return lines (3A713 and 3A005) with a fin pack cooler assembly (5L2Z-3D746-A). 5. Fill and purge the P/S system following the procedures called out in the on-line Workshop Manual Section 211-00. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051715A 2001 Explorer Sport Trac 2.2 Hrs. 4X214X4, Explorer Sport 4X214X4 Vehicles Built Before 4-18-2001: Replace The Power Steering Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715A 2001-2002 Explorer Sport 2.2 Hrs. Trac 4X4, Explorer Sport 4X214X4 Vehicles Built After 4-18-01 And Before 11-7-2001: Replace The Power Steering Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715B 2001-2002 Explorer Sport 1.4 Hrs. Trac 4X2 Built After 4-18-2001: Replace The P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715C 2002-2005 Explorer Sport 1.0 Hr. Trac 4X2/4X4 Explorer Sport 4X2/4X4 Built After 11-7-2001: Replace The P/S Cooler, Fill And Purge The P/S System (Do Not Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Cooler: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7301 Use With 3504A, 3504A9, 3674A, 3674D) DEALER CODING CONDITION BASIC PART NO. CODE 3A674 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Cooler: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped Power Steering Fluid Cooler: Customer Interest Steering - Shudder on Low Speed Turns or When Stopped Article No. 03-19-12 09/29/03 ^ STEERING - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS OR AT STOP ^ VIBRATION - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS OR AT STOP FORD: 2001-2003 EXPLORER SPORT 2001-2004 EXPLORER SPORT TRAC This article supersedes TSB 01-25-01 to update the part numbers and the vehicle coverage. ISSUE Some 2001-2004 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction between the tire and the road surface, which is amplified by the steering system. The condition will vary according to ambient temperature, road surface friction, and steering wheel turning speed. ACTION As design changes have taken place in the steering system, it is important to note the vehicle build date and follow the appropriate steps outlined in the following Service Procedure. Per the vehicle build date it may be necessary to replace the power steering pump and cooler, and install a no-hole check valve in the steering gear. Perform a thorough evacuation of air from the power steering system after replacement/installation of parts and reprogram the Powertrain Control Module (PCM) to the latest level calibration. NOTE THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED OF AIR WITH A VACUUM AT THE RESERVOIR. CORRECTLY FOLLOWING THE EVACUATION PROCEDURE DETAILED BELOW WILL REDUCE THE AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER. THE SHUDDER MAY STILL BE PRESENT AFTER REPLACEMENT OF THE PARTS IF THE EVACUATION PROCEDURE IS NOT PROPERLY FOLLOWED. NOTE PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED. SERVICE PROCEDURE VEHICLES BUILT PRIOR TO APRIL 18, 2001 1. Replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. NOTE DO NOT FILL, PURGE, OR LEAK CHECK THE SYSTEM AT THIS POINT SINCE THE STEERING GEAR CHECK VALVE AND COOLER MUST ALSO BE REPLACED. 2. Replace the Cooler Assembly with service part F77Z-30746-GA. (This new cooler has a larger fin pack to maintain lower fluid temperatures). BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the return line on the new cooler to be installed and connect this new fin pack assembly to the existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section 211-02 for complete replacement instructions. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Cooler: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7306 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP. TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL-211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. 4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole Check Valve (E60Z-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the No-Hole Check Valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Cooler: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7307 5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. 6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 8. Recheck the fluid level and, if necessary, refill. 9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 11. Reprogram the PCM to the latest level available. 12. Test drive to verify repair. VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001 1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump (Part Number 1L2Z-3A674-GA) and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. 2. Replace the Cooler Assembly with service part F77Z-3D746-GA. (This new cooler has a larger fin pack to maintain lower fluid temperatures). BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the return line on the new cooler to be installed and connect this new fin pack assembly to the existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. 4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole Check Valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Cooler: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7308 6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 8. Recheck the fluid level and, if necessary, refill. 9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 11. Reprogram the PCM to the latest level available. 12. Test drive to verify repair. VEHICLES BUILT AFTER NOVEMBER 7, 2001 WARNING DO NOT INSTALL THE CHECK VALVE ON VEHICLES BUILT AFTER 11/07/2001. TRYING TO INSTALL THE CHECK VALVE WILL CAUSE DAMAGE TO THE RACK AND IT WILL HAVE TO BE REPLACED. 1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. 2. Check and fill the power steering reservoir as necessary with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. 3. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 4. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 5. Recheck the fluid level and, if necessary, refill. 6. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 7. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Cooler: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7309 NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 8. Reprogram the PCM to the latest level available. (Does not apply to 2003-2004 vehicles) 9. Test drive to verify repair. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PCM Calibration Information Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Cooler: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7310 SUPERSEDES: 01-25-1 WARRANTY STATUS: Eligible Under Provisions Of The New Vehicle Limited Warranty. OPERATION DESCRIPTION TIME 031912A Replace Power Steering 2.4 Hrs. Pump, P/S Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport 031912B Replace Power Steering 2.5 Hrs. Pump, P/S Cooler, Install No Hole Check Valve, Bleed P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S System A Second Time) Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport 031912C Replace Power Steering 1.6 Hrs. Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac 031912D Replace Power Steering 1.8 Hrs. Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S System A Second Time) Vehicles Built After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac 031912E Replace Power Steering 1.9 Hrs. Pump, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4X4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport 031912F Replace Power Steering 2.0 Hrs. Pump, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built After 11-07-01 But Before Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Cooler: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7311 8-19-02 4x4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport 031912G Bleed Air From P/S 1.1 Hrs. System, And Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac 031912H Bleed Air From P/S 1.2 Hrs. System, And Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac 031912I Replace Power Steering 1.4 Hrs. Pump, Bleed Air From P/S System Vehicles 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912J Replace Power Steering 1.8 Hrs. Pump, Bleed Air From P/S System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912K Bleed Air From P/S 0.6 Hrs. System, Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912L Bleed Air From P/S 1.0 Hrs. System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport DEALER CODING CONDITION BASIC PART NO. CODE 3A674 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Cooler: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns Power Steering Fluid Cooler: All Technical Service Bulletins Steering - Shudder on Low Speed Turns TSB 05-17-15 09/05/05 STEERING SHUDDER DURING LOW SPEED MANEUVERS - 4.0L ENGINE FORD: 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac This article supersedes TSB 04-2-7 to update the vehicle model years and service procedure. ISSUE Some 2001-2005 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction between the tire and the road surface, which is amplified through the steering system. The condition will vary according to ambient temperature, road surface friction, and steering wheel turning speed. ACTION As design changes have taken place in the steering system, it is important to note the VEHICLE BUILD DATE and follow the appropriate steps outlined in the following Service Procedure. Perform a thorough evacuation of air from the power steering system after replacement/installation of parts. SERVICE PROCEDURE NOTE BEFORE REPLACING ANY COMPONENT, BE SURE TO CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. NOTE THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED OF AIR WITH A VACUUM AT THE RESERVOIR. FILL AND PURGE THE P/S SYSTEM FOLLOWING THE PROCEDURES CALLED OUT IN THE ON-LINE WORKSHOP MANUAL, SECTION 211-00. FOLLOWING THE EVACUATION PROCEDURE WILL REDUCE THE AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER. NOTE PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED. VEHICLES BUILT PRIOR TO APRIL 18, 2001 1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer to Workshop Manual, Section 211-02. 2. Replace the cooler assembly with service part F77Z-3D746-GA. Do not remove the existing cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the new return line from the new cooler and connect the new cooler fin pack to the existing return line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid loss from the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Cooler: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7317 4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figures 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section 211-00. 6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release B28.5 or higher. Calibration files may also be obtained at the website. VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001 NOTE FOR ALL 4X2 SPORT TRAC VEHICLES BUILT AFTER 4/18/2001, PROCEED DIRECTLY TO STEP 2. THESE VEHICLES ARE ALREADY EQUIPPED WITH THE HIGH OUTPUT DISPLACEMENT PUMP (5L2Z-3A674-CA). 1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer to the Workshop Manual, Section 211-02. 2. Replace the cooler assembly with service part (F77Z-3D746-GA). Do not remove the existing cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the new return line from the new cooler and connect the new cooler fin pack to the existing return line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid loss from the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Cooler: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7318 4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section 211-00. 6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release B28.5 or higher. Calibration files may also be obtained at the website. VEHICLES BUILT AFTER NOVEMBER 7, 2001 1. Remove the power steering cooler (Figure 3) from the steering gear. 2. Remove the return line from the power steering reservoir bottle (Figure 4). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Cooler: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7319 3. Remove the return line from the steering gear (Figure 5). 4. Replace the current cooler (3D746) and two return lines (3A713 and 3A005) with a fin pack cooler assembly (5L2Z-3D746-A). 5. Fill and purge the P/S system following the procedures called out in the on-line Workshop Manual Section 211-00. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051715A 2001 Explorer Sport Trac 2.2 Hrs. 4X214X4, Explorer Sport 4X214X4 Vehicles Built Before 4-18-2001: Replace The Power Steering Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715A 2001-2002 Explorer Sport 2.2 Hrs. Trac 4X4, Explorer Sport 4X214X4 Vehicles Built After 4-18-01 And Before 11-7-2001: Replace The Power Steering Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715B 2001-2002 Explorer Sport 1.4 Hrs. Trac 4X2 Built After 4-18-2001: Replace The P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715C 2002-2005 Explorer Sport 1.0 Hr. Trac 4X2/4X4 Explorer Sport 4X2/4X4 Built After 11-7-2001: Replace The P/S Cooler, Fill And Purge The P/S System (Do Not Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Cooler: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7320 Use With 3504A, 3504A9, 3674A, 3674D) DEALER CODING CONDITION BASIC PART NO. CODE 3A674 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Cooler: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped Power Steering Fluid Cooler: All Technical Service Bulletins Steering - Shudder on Low Speed Turns or When Stopped Article No. 03-19-12 09/29/03 ^ STEERING - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS OR AT STOP ^ VIBRATION - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS OR AT STOP FORD: 2001-2003 EXPLORER SPORT 2001-2004 EXPLORER SPORT TRAC This article supersedes TSB 01-25-01 to update the part numbers and the vehicle coverage. ISSUE Some 2001-2004 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction between the tire and the road surface, which is amplified by the steering system. The condition will vary according to ambient temperature, road surface friction, and steering wheel turning speed. ACTION As design changes have taken place in the steering system, it is important to note the vehicle build date and follow the appropriate steps outlined in the following Service Procedure. Per the vehicle build date it may be necessary to replace the power steering pump and cooler, and install a no-hole check valve in the steering gear. Perform a thorough evacuation of air from the power steering system after replacement/installation of parts and reprogram the Powertrain Control Module (PCM) to the latest level calibration. NOTE THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED OF AIR WITH A VACUUM AT THE RESERVOIR. CORRECTLY FOLLOWING THE EVACUATION PROCEDURE DETAILED BELOW WILL REDUCE THE AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER. THE SHUDDER MAY STILL BE PRESENT AFTER REPLACEMENT OF THE PARTS IF THE EVACUATION PROCEDURE IS NOT PROPERLY FOLLOWED. NOTE PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED. SERVICE PROCEDURE VEHICLES BUILT PRIOR TO APRIL 18, 2001 1. Replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. NOTE DO NOT FILL, PURGE, OR LEAK CHECK THE SYSTEM AT THIS POINT SINCE THE STEERING GEAR CHECK VALVE AND COOLER MUST ALSO BE REPLACED. 2. Replace the Cooler Assembly with service part F77Z-30746-GA. (This new cooler has a larger fin pack to maintain lower fluid temperatures). BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the return line on the new cooler to be installed and connect this new fin pack assembly to the existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section 211-02 for complete replacement instructions. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Cooler: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7325 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP. TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL-211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. 4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole Check Valve (E60Z-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the No-Hole Check Valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Cooler: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7326 5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. 6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 8. Recheck the fluid level and, if necessary, refill. 9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 11. Reprogram the PCM to the latest level available. 12. Test drive to verify repair. VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001 1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump (Part Number 1L2Z-3A674-GA) and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. 2. Replace the Cooler Assembly with service part F77Z-3D746-GA. (This new cooler has a larger fin pack to maintain lower fluid temperatures). BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the return line on the new cooler to be installed and connect this new fin pack assembly to the existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. 4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole Check Valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Cooler: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7327 6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 8. Recheck the fluid level and, if necessary, refill. 9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 11. Reprogram the PCM to the latest level available. 12. Test drive to verify repair. VEHICLES BUILT AFTER NOVEMBER 7, 2001 WARNING DO NOT INSTALL THE CHECK VALVE ON VEHICLES BUILT AFTER 11/07/2001. TRYING TO INSTALL THE CHECK VALVE WILL CAUSE DAMAGE TO THE RACK AND IT WILL HAVE TO BE REPLACED. 1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. 2. Check and fill the power steering reservoir as necessary with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. 3. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 4. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 5. Recheck the fluid level and, if necessary, refill. 6. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 7. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Cooler: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7328 NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 8. Reprogram the PCM to the latest level available. (Does not apply to 2003-2004 vehicles) 9. Test drive to verify repair. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PCM Calibration Information Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Cooler: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7329 SUPERSEDES: 01-25-1 WARRANTY STATUS: Eligible Under Provisions Of The New Vehicle Limited Warranty. OPERATION DESCRIPTION TIME 031912A Replace Power Steering 2.4 Hrs. Pump, P/S Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport 031912B Replace Power Steering 2.5 Hrs. Pump, P/S Cooler, Install No Hole Check Valve, Bleed P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S System A Second Time) Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport 031912C Replace Power Steering 1.6 Hrs. Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac 031912D Replace Power Steering 1.8 Hrs. Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S System A Second Time) Vehicles Built After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac 031912E Replace Power Steering 1.9 Hrs. Pump, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4X4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport 031912F Replace Power Steering 2.0 Hrs. Pump, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built After 11-07-01 But Before Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Cooler: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7330 8-19-02 4x4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport 031912G Bleed Air From P/S 1.1 Hrs. System, And Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac 031912H Bleed Air From P/S 1.2 Hrs. System, And Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac 031912I Replace Power Steering 1.4 Hrs. Pump, Bleed Air From P/S System Vehicles 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912J Replace Power Steering 1.8 Hrs. Pump, Bleed Air From P/S System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912K Bleed Air From P/S 0.6 Hrs. System, Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912L Bleed Air From P/S 1.0 Hrs. System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport DEALER CODING CONDITION BASIC PART NO. CODE 3A674 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > Page 7331 Power Steering Fluid Cooler: Specifications Power Steering Fluid Cooler Nuts ............................................................................................................................................................ 80 Nm (59 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > Page 7332 Power Steering Fluid Cooler: Service and Repair Power Steering Fluid Cooler Removal and Installation 1. Raise and support the vehicle. 2. Disconnect the power steering return hose at the power steering fluid cooler. ^ Drain the fluid into a suitable container. 3. Remove the power steering fluid cooler to crossmember nuts. 4. Disconnect the power steering return line hose. Remove the power steering fluid cooler. 5. To install, reverse the removal procedure. ^ Fill, purge and leak check the system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications Power Steering Pressure Hose To Power Steering Pump ......................................................................................................................... 65 Nm (48 ft. lbs.) Steering Line To Gear Clamp Plate Nut ................................................................................................................................................... 25 Nm (18 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications > Page 7336 Power Steering Line/Hose: Service and Repair Hose Special Tools Special Tool(s) Removal and Installation CAUTION: While servicing the power steering system, make sure to plug all open hoses, line fittings, and fluid ports to prevent the entry of contaminants or premature failure of the power steering components can result. 1. Refer to the System View illustration for the hose routing and retention points. 2. When connecting a fitting with a seal ring, a new seal ring must be installed. ^ The special tool is used to install the return line connector seal and the pressure line connector seal. 3. Fill, purge and leak check the system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pressure Control Valve: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns Power Steering Pressure Control Valve: Customer Interest Steering - Shudder on Low Speed Turns TSB 05-17-15 09/05/05 STEERING SHUDDER DURING LOW SPEED MANEUVERS - 4.0L ENGINE FORD: 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac This article supersedes TSB 04-2-7 to update the vehicle model years and service procedure. ISSUE Some 2001-2005 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction between the tire and the road surface, which is amplified through the steering system. The condition will vary according to ambient temperature, road surface friction, and steering wheel turning speed. ACTION As design changes have taken place in the steering system, it is important to note the VEHICLE BUILD DATE and follow the appropriate steps outlined in the following Service Procedure. Perform a thorough evacuation of air from the power steering system after replacement/installation of parts. SERVICE PROCEDURE NOTE BEFORE REPLACING ANY COMPONENT, BE SURE TO CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. NOTE THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED OF AIR WITH A VACUUM AT THE RESERVOIR. FILL AND PURGE THE P/S SYSTEM FOLLOWING THE PROCEDURES CALLED OUT IN THE ON-LINE WORKSHOP MANUAL, SECTION 211-00. FOLLOWING THE EVACUATION PROCEDURE WILL REDUCE THE AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER. NOTE PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED. VEHICLES BUILT PRIOR TO APRIL 18, 2001 1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer to Workshop Manual, Section 211-02. 2. Replace the cooler assembly with service part F77Z-3D746-GA. Do not remove the existing cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the new return line from the new cooler and connect the new cooler fin pack to the existing return line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid loss from the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pressure Control Valve: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7345 4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figures 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section 211-00. 6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release B28.5 or higher. Calibration files may also be obtained at the website. VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001 NOTE FOR ALL 4X2 SPORT TRAC VEHICLES BUILT AFTER 4/18/2001, PROCEED DIRECTLY TO STEP 2. THESE VEHICLES ARE ALREADY EQUIPPED WITH THE HIGH OUTPUT DISPLACEMENT PUMP (5L2Z-3A674-CA). 1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer to the Workshop Manual, Section 211-02. 2. Replace the cooler assembly with service part (F77Z-3D746-GA). Do not remove the existing cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the new return line from the new cooler and connect the new cooler fin pack to the existing return line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid loss from the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pressure Control Valve: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7346 4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section 211-00. 6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release B28.5 or higher. Calibration files may also be obtained at the website. VEHICLES BUILT AFTER NOVEMBER 7, 2001 1. Remove the power steering cooler (Figure 3) from the steering gear. 2. Remove the return line from the power steering reservoir bottle (Figure 4). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pressure Control Valve: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7347 3. Remove the return line from the steering gear (Figure 5). 4. Replace the current cooler (3D746) and two return lines (3A713 and 3A005) with a fin pack cooler assembly (5L2Z-3D746-A). 5. Fill and purge the P/S system following the procedures called out in the on-line Workshop Manual Section 211-00. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051715A 2001 Explorer Sport Trac 2.2 Hrs. 4X214X4, Explorer Sport 4X214X4 Vehicles Built Before 4-18-2001: Replace The Power Steering Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715A 2001-2002 Explorer Sport 2.2 Hrs. Trac 4X4, Explorer Sport 4X214X4 Vehicles Built After 4-18-01 And Before 11-7-2001: Replace The Power Steering Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715B 2001-2002 Explorer Sport 1.4 Hrs. Trac 4X2 Built After 4-18-2001: Replace The P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715C 2002-2005 Explorer Sport 1.0 Hr. Trac 4X2/4X4 Explorer Sport 4X2/4X4 Built After 11-7-2001: Replace The P/S Cooler, Fill And Purge The P/S System (Do Not Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pressure Control Valve: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7348 Use With 3504A, 3504A9, 3674A, 3674D) DEALER CODING CONDITION BASIC PART NO. CODE 3A674 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pressure Control Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped Power Steering Pressure Control Valve: Customer Interest Steering - Shudder on Low Speed Turns or When Stopped Article No. 03-19-12 09/29/03 ^ STEERING - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS OR AT STOP ^ VIBRATION - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS OR AT STOP FORD: 2001-2003 EXPLORER SPORT 2001-2004 EXPLORER SPORT TRAC This article supersedes TSB 01-25-01 to update the part numbers and the vehicle coverage. ISSUE Some 2001-2004 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction between the tire and the road surface, which is amplified by the steering system. The condition will vary according to ambient temperature, road surface friction, and steering wheel turning speed. ACTION As design changes have taken place in the steering system, it is important to note the vehicle build date and follow the appropriate steps outlined in the following Service Procedure. Per the vehicle build date it may be necessary to replace the power steering pump and cooler, and install a no-hole check valve in the steering gear. Perform a thorough evacuation of air from the power steering system after replacement/installation of parts and reprogram the Powertrain Control Module (PCM) to the latest level calibration. NOTE THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED OF AIR WITH A VACUUM AT THE RESERVOIR. CORRECTLY FOLLOWING THE EVACUATION PROCEDURE DETAILED BELOW WILL REDUCE THE AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER. THE SHUDDER MAY STILL BE PRESENT AFTER REPLACEMENT OF THE PARTS IF THE EVACUATION PROCEDURE IS NOT PROPERLY FOLLOWED. NOTE PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED. SERVICE PROCEDURE VEHICLES BUILT PRIOR TO APRIL 18, 2001 1. Replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. NOTE DO NOT FILL, PURGE, OR LEAK CHECK THE SYSTEM AT THIS POINT SINCE THE STEERING GEAR CHECK VALVE AND COOLER MUST ALSO BE REPLACED. 2. Replace the Cooler Assembly with service part F77Z-30746-GA. (This new cooler has a larger fin pack to maintain lower fluid temperatures). BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the return line on the new cooler to be installed and connect this new fin pack assembly to the existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section 211-02 for complete replacement instructions. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pressure Control Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7353 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP. TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL-211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. 4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole Check Valve (E60Z-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the No-Hole Check Valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pressure Control Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7354 5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. 6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 8. Recheck the fluid level and, if necessary, refill. 9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 11. Reprogram the PCM to the latest level available. 12. Test drive to verify repair. VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001 1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump (Part Number 1L2Z-3A674-GA) and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. 2. Replace the Cooler Assembly with service part F77Z-3D746-GA. (This new cooler has a larger fin pack to maintain lower fluid temperatures). BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the return line on the new cooler to be installed and connect this new fin pack assembly to the existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. 4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole Check Valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pressure Control Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7355 6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 8. Recheck the fluid level and, if necessary, refill. 9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 11. Reprogram the PCM to the latest level available. 12. Test drive to verify repair. VEHICLES BUILT AFTER NOVEMBER 7, 2001 WARNING DO NOT INSTALL THE CHECK VALVE ON VEHICLES BUILT AFTER 11/07/2001. TRYING TO INSTALL THE CHECK VALVE WILL CAUSE DAMAGE TO THE RACK AND IT WILL HAVE TO BE REPLACED. 1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. 2. Check and fill the power steering reservoir as necessary with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. 3. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 4. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 5. Recheck the fluid level and, if necessary, refill. 6. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 7. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pressure Control Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7356 NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 8. Reprogram the PCM to the latest level available. (Does not apply to 2003-2004 vehicles) 9. Test drive to verify repair. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PCM Calibration Information Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pressure Control Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7357 SUPERSEDES: 01-25-1 WARRANTY STATUS: Eligible Under Provisions Of The New Vehicle Limited Warranty. OPERATION DESCRIPTION TIME 031912A Replace Power Steering 2.4 Hrs. Pump, P/S Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport 031912B Replace Power Steering 2.5 Hrs. Pump, P/S Cooler, Install No Hole Check Valve, Bleed P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S System A Second Time) Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport 031912C Replace Power Steering 1.6 Hrs. Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac 031912D Replace Power Steering 1.8 Hrs. Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S System A Second Time) Vehicles Built After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac 031912E Replace Power Steering 1.9 Hrs. Pump, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4X4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport 031912F Replace Power Steering 2.0 Hrs. Pump, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built After 11-07-01 But Before Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pressure Control Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7358 8-19-02 4x4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport 031912G Bleed Air From P/S 1.1 Hrs. System, And Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac 031912H Bleed Air From P/S 1.2 Hrs. System, And Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac 031912I Replace Power Steering 1.4 Hrs. Pump, Bleed Air From P/S System Vehicles 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912J Replace Power Steering 1.8 Hrs. Pump, Bleed Air From P/S System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912K Bleed Air From P/S 0.6 Hrs. System, Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912L Bleed Air From P/S 1.0 Hrs. System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport DEALER CODING CONDITION BASIC PART NO. CODE 3A674 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Control Valve: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns Power Steering Pressure Control Valve: All Technical Service Bulletins Steering - Shudder on Low Speed Turns TSB 05-17-15 09/05/05 STEERING SHUDDER DURING LOW SPEED MANEUVERS - 4.0L ENGINE FORD: 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac This article supersedes TSB 04-2-7 to update the vehicle model years and service procedure. ISSUE Some 2001-2005 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction between the tire and the road surface, which is amplified through the steering system. The condition will vary according to ambient temperature, road surface friction, and steering wheel turning speed. ACTION As design changes have taken place in the steering system, it is important to note the VEHICLE BUILD DATE and follow the appropriate steps outlined in the following Service Procedure. Perform a thorough evacuation of air from the power steering system after replacement/installation of parts. SERVICE PROCEDURE NOTE BEFORE REPLACING ANY COMPONENT, BE SURE TO CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. NOTE THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED OF AIR WITH A VACUUM AT THE RESERVOIR. FILL AND PURGE THE P/S SYSTEM FOLLOWING THE PROCEDURES CALLED OUT IN THE ON-LINE WORKSHOP MANUAL, SECTION 211-00. FOLLOWING THE EVACUATION PROCEDURE WILL REDUCE THE AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER. NOTE PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED. VEHICLES BUILT PRIOR TO APRIL 18, 2001 1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer to Workshop Manual, Section 211-02. 2. Replace the cooler assembly with service part F77Z-3D746-GA. Do not remove the existing cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the new return line from the new cooler and connect the new cooler fin pack to the existing return line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid loss from the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Control Valve: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7364 4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figures 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section 211-00. 6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release B28.5 or higher. Calibration files may also be obtained at the website. VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001 NOTE FOR ALL 4X2 SPORT TRAC VEHICLES BUILT AFTER 4/18/2001, PROCEED DIRECTLY TO STEP 2. THESE VEHICLES ARE ALREADY EQUIPPED WITH THE HIGH OUTPUT DISPLACEMENT PUMP (5L2Z-3A674-CA). 1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer to the Workshop Manual, Section 211-02. 2. Replace the cooler assembly with service part (F77Z-3D746-GA). Do not remove the existing cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the new return line from the new cooler and connect the new cooler fin pack to the existing return line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid loss from the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Control Valve: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7365 4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section 211-00. 6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release B28.5 or higher. Calibration files may also be obtained at the website. VEHICLES BUILT AFTER NOVEMBER 7, 2001 1. Remove the power steering cooler (Figure 3) from the steering gear. 2. Remove the return line from the power steering reservoir bottle (Figure 4). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Control Valve: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7366 3. Remove the return line from the steering gear (Figure 5). 4. Replace the current cooler (3D746) and two return lines (3A713 and 3A005) with a fin pack cooler assembly (5L2Z-3D746-A). 5. Fill and purge the P/S system following the procedures called out in the on-line Workshop Manual Section 211-00. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051715A 2001 Explorer Sport Trac 2.2 Hrs. 4X214X4, Explorer Sport 4X214X4 Vehicles Built Before 4-18-2001: Replace The Power Steering Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715A 2001-2002 Explorer Sport 2.2 Hrs. Trac 4X4, Explorer Sport 4X214X4 Vehicles Built After 4-18-01 And Before 11-7-2001: Replace The Power Steering Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715B 2001-2002 Explorer Sport 1.4 Hrs. Trac 4X2 Built After 4-18-2001: Replace The P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715C 2002-2005 Explorer Sport 1.0 Hr. Trac 4X2/4X4 Explorer Sport 4X2/4X4 Built After 11-7-2001: Replace The P/S Cooler, Fill And Purge The P/S System (Do Not Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Control Valve: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7367 Use With 3504A, 3504A9, 3674A, 3674D) DEALER CODING CONDITION BASIC PART NO. CODE 3A674 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Control Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped Power Steering Pressure Control Valve: All Technical Service Bulletins Steering - Shudder on Low Speed Turns or When Stopped Article No. 03-19-12 09/29/03 ^ STEERING - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS OR AT STOP ^ VIBRATION - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS OR AT STOP FORD: 2001-2003 EXPLORER SPORT 2001-2004 EXPLORER SPORT TRAC This article supersedes TSB 01-25-01 to update the part numbers and the vehicle coverage. ISSUE Some 2001-2004 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction between the tire and the road surface, which is amplified by the steering system. The condition will vary according to ambient temperature, road surface friction, and steering wheel turning speed. ACTION As design changes have taken place in the steering system, it is important to note the vehicle build date and follow the appropriate steps outlined in the following Service Procedure. Per the vehicle build date it may be necessary to replace the power steering pump and cooler, and install a no-hole check valve in the steering gear. Perform a thorough evacuation of air from the power steering system after replacement/installation of parts and reprogram the Powertrain Control Module (PCM) to the latest level calibration. NOTE THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED OF AIR WITH A VACUUM AT THE RESERVOIR. CORRECTLY FOLLOWING THE EVACUATION PROCEDURE DETAILED BELOW WILL REDUCE THE AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER. THE SHUDDER MAY STILL BE PRESENT AFTER REPLACEMENT OF THE PARTS IF THE EVACUATION PROCEDURE IS NOT PROPERLY FOLLOWED. NOTE PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED. SERVICE PROCEDURE VEHICLES BUILT PRIOR TO APRIL 18, 2001 1. Replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. NOTE DO NOT FILL, PURGE, OR LEAK CHECK THE SYSTEM AT THIS POINT SINCE THE STEERING GEAR CHECK VALVE AND COOLER MUST ALSO BE REPLACED. 2. Replace the Cooler Assembly with service part F77Z-30746-GA. (This new cooler has a larger fin pack to maintain lower fluid temperatures). BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the return line on the new cooler to be installed and connect this new fin pack assembly to the existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section 211-02 for complete replacement instructions. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Control Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7372 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP. TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL-211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. 4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole Check Valve (E60Z-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the No-Hole Check Valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Control Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7373 5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. 6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 8. Recheck the fluid level and, if necessary, refill. 9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 11. Reprogram the PCM to the latest level available. 12. Test drive to verify repair. VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001 1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump (Part Number 1L2Z-3A674-GA) and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. 2. Replace the Cooler Assembly with service part F77Z-3D746-GA. (This new cooler has a larger fin pack to maintain lower fluid temperatures). BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the return line on the new cooler to be installed and connect this new fin pack assembly to the existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. 4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole Check Valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Control Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7374 6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 8. Recheck the fluid level and, if necessary, refill. 9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 11. Reprogram the PCM to the latest level available. 12. Test drive to verify repair. VEHICLES BUILT AFTER NOVEMBER 7, 2001 WARNING DO NOT INSTALL THE CHECK VALVE ON VEHICLES BUILT AFTER 11/07/2001. TRYING TO INSTALL THE CHECK VALVE WILL CAUSE DAMAGE TO THE RACK AND IT WILL HAVE TO BE REPLACED. 1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. 2. Check and fill the power steering reservoir as necessary with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. 3. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 4. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 5. Recheck the fluid level and, if necessary, refill. 6. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 7. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Control Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7375 NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 8. Reprogram the PCM to the latest level available. (Does not apply to 2003-2004 vehicles) 9. Test drive to verify repair. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PCM Calibration Information Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Control Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7376 SUPERSEDES: 01-25-1 WARRANTY STATUS: Eligible Under Provisions Of The New Vehicle Limited Warranty. OPERATION DESCRIPTION TIME 031912A Replace Power Steering 2.4 Hrs. Pump, P/S Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport 031912B Replace Power Steering 2.5 Hrs. Pump, P/S Cooler, Install No Hole Check Valve, Bleed P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S System A Second Time) Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport 031912C Replace Power Steering 1.6 Hrs. Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac 031912D Replace Power Steering 1.8 Hrs. Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S System A Second Time) Vehicles Built After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac 031912E Replace Power Steering 1.9 Hrs. Pump, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4X4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport 031912F Replace Power Steering 2.0 Hrs. Pump, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built After 11-07-01 But Before Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pressure Control Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7377 8-19-02 4x4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport 031912G Bleed Air From P/S 1.1 Hrs. System, And Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac 031912H Bleed Air From P/S 1.2 Hrs. System, And Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac 031912I Replace Power Steering 1.4 Hrs. Pump, Bleed Air From P/S System Vehicles 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912J Replace Power Steering 1.8 Hrs. Pump, Bleed Air From P/S System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912K Bleed Air From P/S 0.6 Hrs. System, Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912L Bleed Air From P/S 1.0 Hrs. System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport DEALER CODING CONDITION BASIC PART NO. CODE 3A674 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pump: > 05-17-15 > Sep > 05 > Steering Shudder on Low Speed Turns Power Steering Pump: Customer Interest Steering - Shudder on Low Speed Turns TSB 05-17-15 09/05/05 STEERING SHUDDER DURING LOW SPEED MANEUVERS - 4.0L ENGINE FORD: 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac This article supersedes TSB 04-2-7 to update the vehicle model years and service procedure. ISSUE Some 2001-2005 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction between the tire and the road surface, which is amplified through the steering system. The condition will vary according to ambient temperature, road surface friction, and steering wheel turning speed. ACTION As design changes have taken place in the steering system, it is important to note the VEHICLE BUILD DATE and follow the appropriate steps outlined in the following Service Procedure. Perform a thorough evacuation of air from the power steering system after replacement/installation of parts. SERVICE PROCEDURE NOTE BEFORE REPLACING ANY COMPONENT, BE SURE TO CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. NOTE THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED OF AIR WITH A VACUUM AT THE RESERVOIR. FILL AND PURGE THE P/S SYSTEM FOLLOWING THE PROCEDURES CALLED OUT IN THE ON-LINE WORKSHOP MANUAL, SECTION 211-00. FOLLOWING THE EVACUATION PROCEDURE WILL REDUCE THE AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER. NOTE PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED. VEHICLES BUILT PRIOR TO APRIL 18, 2001 1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer to Workshop Manual, Section 211-02. 2. Replace the cooler assembly with service part F77Z-3D746-GA. Do not remove the existing cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the new return line from the new cooler and connect the new cooler fin pack to the existing return line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid loss from the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pump: > 05-17-15 > Sep > 05 > Steering Shudder on Low Speed Turns > Page 7386 4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figures 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section 211-00. 6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release B28.5 or higher. Calibration files may also be obtained at the website. VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001 NOTE FOR ALL 4X2 SPORT TRAC VEHICLES BUILT AFTER 4/18/2001, PROCEED DIRECTLY TO STEP 2. THESE VEHICLES ARE ALREADY EQUIPPED WITH THE HIGH OUTPUT DISPLACEMENT PUMP (5L2Z-3A674-CA). 1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer to the Workshop Manual, Section 211-02. 2. Replace the cooler assembly with service part (F77Z-3D746-GA). Do not remove the existing cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the new return line from the new cooler and connect the new cooler fin pack to the existing return line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid loss from the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pump: > 05-17-15 > Sep > 05 > Steering Shudder on Low Speed Turns > Page 7387 4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section 211-00. 6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release B28.5 or higher. Calibration files may also be obtained at the website. VEHICLES BUILT AFTER NOVEMBER 7, 2001 1. Remove the power steering cooler (Figure 3) from the steering gear. 2. Remove the return line from the power steering reservoir bottle (Figure 4). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pump: > 05-17-15 > Sep > 05 > Steering Shudder on Low Speed Turns > Page 7388 3. Remove the return line from the steering gear (Figure 5). 4. Replace the current cooler (3D746) and two return lines (3A713 and 3A005) with a fin pack cooler assembly (5L2Z-3D746-A). 5. Fill and purge the P/S system following the procedures called out in the on-line Workshop Manual Section 211-00. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051715A 2001 Explorer Sport Trac 2.2 Hrs. 4X214X4, Explorer Sport 4X214X4 Vehicles Built Before 4-18-2001: Replace The Power Steering Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715A 2001-2002 Explorer Sport 2.2 Hrs. Trac 4X4, Explorer Sport 4X214X4 Vehicles Built After 4-18-01 And Before 11-7-2001: Replace The Power Steering Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715B 2001-2002 Explorer Sport 1.4 Hrs. Trac 4X2 Built After 4-18-2001: Replace The P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715C 2002-2005 Explorer Sport 1.0 Hr. Trac 4X2/4X4 Explorer Sport 4X2/4X4 Built After 11-7-2001: Replace The P/S Cooler, Fill And Purge The P/S System (Do Not Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pump: > 05-17-15 > Sep > 05 > Steering Shudder on Low Speed Turns > Page 7389 Use With 3504A, 3504A9, 3674A, 3674D) DEALER CODING CONDITION BASIC PART NO. CODE 3A674 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pump: > 03-19-12 > Sep > 03 > Steering Shudder on Low Speed Turns or When Stopped Power Steering Pump: Customer Interest Steering - Shudder on Low Speed Turns or When Stopped Article No. 03-19-12 09/29/03 ^ STEERING - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS OR AT STOP ^ VIBRATION - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS OR AT STOP FORD: 2001-2003 EXPLORER SPORT 2001-2004 EXPLORER SPORT TRAC This article supersedes TSB 01-25-01 to update the part numbers and the vehicle coverage. ISSUE Some 2001-2004 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction between the tire and the road surface, which is amplified by the steering system. The condition will vary according to ambient temperature, road surface friction, and steering wheel turning speed. ACTION As design changes have taken place in the steering system, it is important to note the vehicle build date and follow the appropriate steps outlined in the following Service Procedure. Per the vehicle build date it may be necessary to replace the power steering pump and cooler, and install a no-hole check valve in the steering gear. Perform a thorough evacuation of air from the power steering system after replacement/installation of parts and reprogram the Powertrain Control Module (PCM) to the latest level calibration. NOTE THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED OF AIR WITH A VACUUM AT THE RESERVOIR. CORRECTLY FOLLOWING THE EVACUATION PROCEDURE DETAILED BELOW WILL REDUCE THE AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER. THE SHUDDER MAY STILL BE PRESENT AFTER REPLACEMENT OF THE PARTS IF THE EVACUATION PROCEDURE IS NOT PROPERLY FOLLOWED. NOTE PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED. SERVICE PROCEDURE VEHICLES BUILT PRIOR TO APRIL 18, 2001 1. Replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. NOTE DO NOT FILL, PURGE, OR LEAK CHECK THE SYSTEM AT THIS POINT SINCE THE STEERING GEAR CHECK VALVE AND COOLER MUST ALSO BE REPLACED. 2. Replace the Cooler Assembly with service part F77Z-30746-GA. (This new cooler has a larger fin pack to maintain lower fluid temperatures). BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the return line on the new cooler to be installed and connect this new fin pack assembly to the existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section 211-02 for complete replacement instructions. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pump: > 03-19-12 > Sep > 03 > Steering Shudder on Low Speed Turns or When Stopped > Page 7394 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP. TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL-211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. 4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole Check Valve (E60Z-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the No-Hole Check Valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pump: > 03-19-12 > Sep > 03 > Steering Shudder on Low Speed Turns or When Stopped > Page 7395 5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. 6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 8. Recheck the fluid level and, if necessary, refill. 9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 11. Reprogram the PCM to the latest level available. 12. Test drive to verify repair. VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001 1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump (Part Number 1L2Z-3A674-GA) and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. 2. Replace the Cooler Assembly with service part F77Z-3D746-GA. (This new cooler has a larger fin pack to maintain lower fluid temperatures). BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the return line on the new cooler to be installed and connect this new fin pack assembly to the existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. 4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole Check Valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pump: > 03-19-12 > Sep > 03 > Steering Shudder on Low Speed Turns or When Stopped > Page 7396 6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 8. Recheck the fluid level and, if necessary, refill. 9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 11. Reprogram the PCM to the latest level available. 12. Test drive to verify repair. VEHICLES BUILT AFTER NOVEMBER 7, 2001 WARNING DO NOT INSTALL THE CHECK VALVE ON VEHICLES BUILT AFTER 11/07/2001. TRYING TO INSTALL THE CHECK VALVE WILL CAUSE DAMAGE TO THE RACK AND IT WILL HAVE TO BE REPLACED. 1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. 2. Check and fill the power steering reservoir as necessary with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. 3. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 4. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 5. Recheck the fluid level and, if necessary, refill. 6. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 7. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pump: > 03-19-12 > Sep > 03 > Steering Shudder on Low Speed Turns or When Stopped > Page 7397 NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 8. Reprogram the PCM to the latest level available. (Does not apply to 2003-2004 vehicles) 9. Test drive to verify repair. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PCM Calibration Information Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pump: > 03-19-12 > Sep > 03 > Steering Shudder on Low Speed Turns or When Stopped > Page 7398 SUPERSEDES: 01-25-1 WARRANTY STATUS: Eligible Under Provisions Of The New Vehicle Limited Warranty. OPERATION DESCRIPTION TIME 031912A Replace Power Steering 2.4 Hrs. Pump, P/S Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport 031912B Replace Power Steering 2.5 Hrs. Pump, P/S Cooler, Install No Hole Check Valve, Bleed P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S System A Second Time) Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport 031912C Replace Power Steering 1.6 Hrs. Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac 031912D Replace Power Steering 1.8 Hrs. Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S System A Second Time) Vehicles Built After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac 031912E Replace Power Steering 1.9 Hrs. Pump, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4X4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport 031912F Replace Power Steering 2.0 Hrs. Pump, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built After 11-07-01 But Before Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pump: > 03-19-12 > Sep > 03 > Steering Shudder on Low Speed Turns or When Stopped > Page 7399 8-19-02 4x4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport 031912G Bleed Air From P/S 1.1 Hrs. System, And Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac 031912H Bleed Air From P/S 1.2 Hrs. System, And Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac 031912I Replace Power Steering 1.4 Hrs. Pump, Bleed Air From P/S System Vehicles 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912J Replace Power Steering 1.8 Hrs. Pump, Bleed Air From P/S System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912K Bleed Air From P/S 0.6 Hrs. System, Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912L Bleed Air From P/S 1.0 Hrs. System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport DEALER CODING CONDITION BASIC PART NO. CODE 3A674 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns Power Steering Pump: All Technical Service Bulletins Steering - Shudder on Low Speed Turns TSB 05-17-15 09/05/05 STEERING SHUDDER DURING LOW SPEED MANEUVERS - 4.0L ENGINE FORD: 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac This article supersedes TSB 04-2-7 to update the vehicle model years and service procedure. ISSUE Some 2001-2005 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction between the tire and the road surface, which is amplified through the steering system. The condition will vary according to ambient temperature, road surface friction, and steering wheel turning speed. ACTION As design changes have taken place in the steering system, it is important to note the VEHICLE BUILD DATE and follow the appropriate steps outlined in the following Service Procedure. Perform a thorough evacuation of air from the power steering system after replacement/installation of parts. SERVICE PROCEDURE NOTE BEFORE REPLACING ANY COMPONENT, BE SURE TO CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. NOTE THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED OF AIR WITH A VACUUM AT THE RESERVOIR. FILL AND PURGE THE P/S SYSTEM FOLLOWING THE PROCEDURES CALLED OUT IN THE ON-LINE WORKSHOP MANUAL, SECTION 211-00. FOLLOWING THE EVACUATION PROCEDURE WILL REDUCE THE AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER. NOTE PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED. VEHICLES BUILT PRIOR TO APRIL 18, 2001 1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer to Workshop Manual, Section 211-02. 2. Replace the cooler assembly with service part F77Z-3D746-GA. Do not remove the existing cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the new return line from the new cooler and connect the new cooler fin pack to the existing return line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid loss from the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7405 4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figures 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section 211-00. 6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release B28.5 or higher. Calibration files may also be obtained at the website. VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001 NOTE FOR ALL 4X2 SPORT TRAC VEHICLES BUILT AFTER 4/18/2001, PROCEED DIRECTLY TO STEP 2. THESE VEHICLES ARE ALREADY EQUIPPED WITH THE HIGH OUTPUT DISPLACEMENT PUMP (5L2Z-3A674-CA). 1. Replace the power steering pump with a new high displacement pump (5L2Z-3A674-CA). Refer to the Workshop Manual, Section 211-02. 2. Replace the cooler assembly with service part (F77Z-3D746-GA). Do not remove the existing cooler return line (hose attached to the gear outlet port) it will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid loss during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the new return line from the new cooler and connect the new cooler fin pack to the existing return line. Re-secure the constant tension clamp. Refer to Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid loss from the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7406 4. Replace the check valve located in the steering gear pressure side inlet port with a no-hole check valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill and purge the P/S system following the procedures in the on-line Workshop Manual Section 211-00. 6. Reprogram the powertrain control module (PCM) to the latest calibration using WDS release B28.5 or higher. Calibration files may also be obtained at the website. VEHICLES BUILT AFTER NOVEMBER 7, 2001 1. Remove the power steering cooler (Figure 3) from the steering gear. 2. Remove the return line from the power steering reservoir bottle (Figure 4). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7407 3. Remove the return line from the steering gear (Figure 5). 4. Replace the current cooler (3D746) and two return lines (3A713 and 3A005) with a fin pack cooler assembly (5L2Z-3D746-A). 5. Fill and purge the P/S system following the procedures called out in the on-line Workshop Manual Section 211-00. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051715A 2001 Explorer Sport Trac 2.2 Hrs. 4X214X4, Explorer Sport 4X214X4 Vehicles Built Before 4-18-2001: Replace The Power Steering Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715A 2001-2002 Explorer Sport 2.2 Hrs. Trac 4X4, Explorer Sport 4X214X4 Vehicles Built After 4-18-01 And Before 11-7-2001: Replace The Power Steering Pump, P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715B 2001-2002 Explorer Sport 1.4 Hrs. Trac 4X2 Built After 4-18-2001: Replace The P/S Cooler, Install No Hole Check Valve, Fill And Purge The P/S System, Reprogram The Powertrain Control Module (Do Not Use With 3504A, 3504A9, 3674A, 3674D) 051715C 2002-2005 Explorer Sport 1.0 Hr. Trac 4X2/4X4 Explorer Sport 4X2/4X4 Built After 11-7-2001: Replace The P/S Cooler, Fill And Purge The P/S System (Do Not Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 05-17-15 > Sep > 05 > Steering - Shudder on Low Speed Turns > Page 7408 Use With 3504A, 3504A9, 3674A, 3674D) DEALER CODING CONDITION BASIC PART NO. CODE 3A674 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped Power Steering Pump: All Technical Service Bulletins Steering - Shudder on Low Speed Turns or When Stopped Article No. 03-19-12 09/29/03 ^ STEERING - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS OR AT STOP ^ VIBRATION - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS OR AT STOP FORD: 2001-2003 EXPLORER SPORT 2001-2004 EXPLORER SPORT TRAC This article supersedes TSB 01-25-01 to update the part numbers and the vehicle coverage. ISSUE Some 2001-2004 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction between the tire and the road surface, which is amplified by the steering system. The condition will vary according to ambient temperature, road surface friction, and steering wheel turning speed. ACTION As design changes have taken place in the steering system, it is important to note the vehicle build date and follow the appropriate steps outlined in the following Service Procedure. Per the vehicle build date it may be necessary to replace the power steering pump and cooler, and install a no-hole check valve in the steering gear. Perform a thorough evacuation of air from the power steering system after replacement/installation of parts and reprogram the Powertrain Control Module (PCM) to the latest level calibration. NOTE THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED OF AIR WITH A VACUUM AT THE RESERVOIR. CORRECTLY FOLLOWING THE EVACUATION PROCEDURE DETAILED BELOW WILL REDUCE THE AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER. THE SHUDDER MAY STILL BE PRESENT AFTER REPLACEMENT OF THE PARTS IF THE EVACUATION PROCEDURE IS NOT PROPERLY FOLLOWED. NOTE PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED. SERVICE PROCEDURE VEHICLES BUILT PRIOR TO APRIL 18, 2001 1. Replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. NOTE DO NOT FILL, PURGE, OR LEAK CHECK THE SYSTEM AT THIS POINT SINCE THE STEERING GEAR CHECK VALVE AND COOLER MUST ALSO BE REPLACED. 2. Replace the Cooler Assembly with service part F77Z-30746-GA. (This new cooler has a larger fin pack to maintain lower fluid temperatures). BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the return line on the new cooler to be installed and connect this new fin pack assembly to the existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section 211-02 for complete replacement instructions. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7413 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP. TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL-211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. 4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole Check Valve (E60Z-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the No-Hole Check Valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7414 5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. 6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 8. Recheck the fluid level and, if necessary, refill. 9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 11. Reprogram the PCM to the latest level available. 12. Test drive to verify repair. VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001 1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump (Part Number 1L2Z-3A674-GA) and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. 2. Replace the Cooler Assembly with service part F77Z-3D746-GA. (This new cooler has a larger fin pack to maintain lower fluid temperatures). BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the return line on the new cooler to be installed and connect this new fin pack assembly to the existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. 4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole Check Valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7415 6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 8. Recheck the fluid level and, if necessary, refill. 9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 11. Reprogram the PCM to the latest level available. 12. Test drive to verify repair. VEHICLES BUILT AFTER NOVEMBER 7, 2001 WARNING DO NOT INSTALL THE CHECK VALVE ON VEHICLES BUILT AFTER 11/07/2001. TRYING TO INSTALL THE CHECK VALVE WILL CAUSE DAMAGE TO THE RACK AND IT WILL HAVE TO BE REPLACED. 1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. 2. Check and fill the power steering reservoir as necessary with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. 3. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 4. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 5. Recheck the fluid level and, if necessary, refill. 6. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 7. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7416 NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 8. Reprogram the PCM to the latest level available. (Does not apply to 2003-2004 vehicles) 9. Test drive to verify repair. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PCM Calibration Information Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7417 SUPERSEDES: 01-25-1 WARRANTY STATUS: Eligible Under Provisions Of The New Vehicle Limited Warranty. OPERATION DESCRIPTION TIME 031912A Replace Power Steering 2.4 Hrs. Pump, P/S Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport 031912B Replace Power Steering 2.5 Hrs. Pump, P/S Cooler, Install No Hole Check Valve, Bleed P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S System A Second Time) Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport 031912C Replace Power Steering 1.6 Hrs. Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac 031912D Replace Power Steering 1.8 Hrs. Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S System A Second Time) Vehicles Built After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac 031912E Replace Power Steering 1.9 Hrs. Pump, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4X4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport 031912F Replace Power Steering 2.0 Hrs. Pump, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built After 11-07-01 But Before Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7418 8-19-02 4x4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport 031912G Bleed Air From P/S 1.1 Hrs. System, And Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac 031912H Bleed Air From P/S 1.2 Hrs. System, And Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac 031912I Replace Power Steering 1.4 Hrs. Pump, Bleed Air From P/S System Vehicles 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912J Replace Power Steering 1.8 Hrs. Pump, Bleed Air From P/S System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912K Bleed Air From P/S 0.6 Hrs. System, Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912L Bleed Air From P/S 1.0 Hrs. System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport DEALER CODING CONDITION BASIC PART NO. CODE 3A674 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications Power Steering Pump: Mechanical Specifications Power Steering Pump Bolts ................................................................................................................. ..................................................... 25 Nm (18 ft. lbs.) Power Steering Pump Pulley Bolts ........................................................................................................................................................... 25 Nm (18 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications > Page 7421 Power Steering Pump: Pressure, Vacuum and Temperature Specifications Power Steering Pump Flow .................................. 8.3 - 9.8 liters/minute (2.2-2.6 gpm) fluid @ 74 degrees - 80 degrees C (165 degrees - 175 degrees F) engine at 1,500 rpm Pressure ....................................................... 1,034 kPa (150 psi) fluid @ 74 degrees - 80 degrees C (165 degrees - 175 degrees F) engine at 1,500 rpm Minimum Capacity .............. 4.35 liters/minute (1.15 gpm) fluid @ 74 degrees - 80 degrees C (165 degrees - 175 degrees F) engine at idle pressure at 5,171 kPa (750 psi) Relief pressure ....................................................................................................................................................... 8,946 - 10,205 kPa (1,300 - 1,480 psi) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Application and ID > Pump Power Steering Pump Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Application and ID > Pump > Page 7424 Power Steering Pump: Application and ID Pump Identification Pump Identification CAUTION: Always use the ID code when ordering service parts. The pump identification code is located on a tag attached to the power steering pump. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Power Steering Pump: Service and Repair Power Steering Pump Power Steering Pump Special Tools Special Tool(s) Removal 1. Remove the engine cooling fan. 2. Loosen the power steering pump pulley bolts. 3. Remove the drive belt. 4. Remove the power steering pump pulley. 1 Remove the bolts. 2 Remove the power steering pump pulley. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 7427 5. Disconnect the power steering return line hose at the power steering fluid reservoir. ^ Allow the system to drain. 6. Disconnect the power steering pressure hose from the power steering pump. 7. Disconnect the power steering fluid reservoir outlet hose from the power steering pump. 1 Compress and move the power steering fluid reservoir outlet hose clamp. 2 Disconnect the power steering fluid reservoir outlet hose from the power steering pump. 8. Remove the power steering pump. 1 Remove the bolts. 2 Remove the power steering pump. Installation Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 7428 1. Install the power steering pump. 1 Position the power steering pump. 2 Install the bolts. 2. Connect the power steering fluid reservoir outlet hose to the power steering pump. 1 Connect the power steering fluid reservoir outlet hose to the power steering pump. 2 Compress and move the power steering fluid reservoir outlet hose clamp into place. 3. Using the special tool, install a new seal on the power steering pressure hose. 4. Connect the power steering pressure hose to the power steering pump. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 7429 5. Connect the power steering return line hose to the power steering fluid reservoir. 6. Install the power steering pump pulley. 1 Position the power steering pump pulley. 2 Install the bolts. 7. Install the drive belt. 8. Tighten the power steering pump pulley bolts. 9. Install the engine cooling fan. 10. Fill, purge and leak check the system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 7430 Power Steering Pump: Service and Repair Power Steering Pump Pulley Power Steering Pump Pulley Removal and Installation 1. Remove the engine cooling fan. 2. Loosen the power steering pump pulley bolts. 3. Remove the drive belt. 4. Remove the power steering pump pulley. 1 Remove the bolts. 2 Remove the power steering pump pulley. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Valve: > 03-19-12 > Sep > 03 > Steering Shudder on Low Speed Turns or When Stopped Power Steering Valve: Customer Interest Steering - Shudder on Low Speed Turns or When Stopped Article No. 03-19-12 09/29/03 ^ STEERING - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS OR AT STOP ^ VIBRATION - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS OR AT STOP FORD: 2001-2003 EXPLORER SPORT 2001-2004 EXPLORER SPORT TRAC This article supersedes TSB 01-25-01 to update the part numbers and the vehicle coverage. ISSUE Some 2001-2004 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction between the tire and the road surface, which is amplified by the steering system. The condition will vary according to ambient temperature, road surface friction, and steering wheel turning speed. ACTION As design changes have taken place in the steering system, it is important to note the vehicle build date and follow the appropriate steps outlined in the following Service Procedure. Per the vehicle build date it may be necessary to replace the power steering pump and cooler, and install a no-hole check valve in the steering gear. Perform a thorough evacuation of air from the power steering system after replacement/installation of parts and reprogram the Powertrain Control Module (PCM) to the latest level calibration. NOTE THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED OF AIR WITH A VACUUM AT THE RESERVOIR. CORRECTLY FOLLOWING THE EVACUATION PROCEDURE DETAILED BELOW WILL REDUCE THE AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER. THE SHUDDER MAY STILL BE PRESENT AFTER REPLACEMENT OF THE PARTS IF THE EVACUATION PROCEDURE IS NOT PROPERLY FOLLOWED. NOTE PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED. SERVICE PROCEDURE VEHICLES BUILT PRIOR TO APRIL 18, 2001 1. Replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. NOTE DO NOT FILL, PURGE, OR LEAK CHECK THE SYSTEM AT THIS POINT SINCE THE STEERING GEAR CHECK VALVE AND COOLER MUST ALSO BE REPLACED. 2. Replace the Cooler Assembly with service part F77Z-30746-GA. (This new cooler has a larger fin pack to maintain lower fluid temperatures). BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the return line on the new cooler to be installed and connect this new fin pack assembly to the existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section 211-02 for complete replacement instructions. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Valve: > 03-19-12 > Sep > 03 > Steering Shudder on Low Speed Turns or When Stopped > Page 7439 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP. TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL-211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. 4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole Check Valve (E60Z-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the No-Hole Check Valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Valve: > 03-19-12 > Sep > 03 > Steering Shudder on Low Speed Turns or When Stopped > Page 7440 5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. 6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 8. Recheck the fluid level and, if necessary, refill. 9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 11. Reprogram the PCM to the latest level available. 12. Test drive to verify repair. VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001 1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump (Part Number 1L2Z-3A674-GA) and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. 2. Replace the Cooler Assembly with service part F77Z-3D746-GA. (This new cooler has a larger fin pack to maintain lower fluid temperatures). BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the return line on the new cooler to be installed and connect this new fin pack assembly to the existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. 4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole Check Valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Valve: > 03-19-12 > Sep > 03 > Steering Shudder on Low Speed Turns or When Stopped > Page 7441 6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 8. Recheck the fluid level and, if necessary, refill. 9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 11. Reprogram the PCM to the latest level available. 12. Test drive to verify repair. VEHICLES BUILT AFTER NOVEMBER 7, 2001 WARNING DO NOT INSTALL THE CHECK VALVE ON VEHICLES BUILT AFTER 11/07/2001. TRYING TO INSTALL THE CHECK VALVE WILL CAUSE DAMAGE TO THE RACK AND IT WILL HAVE TO BE REPLACED. 1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. 2. Check and fill the power steering reservoir as necessary with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. 3. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 4. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 5. Recheck the fluid level and, if necessary, refill. 6. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 7. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Valve: > 03-19-12 > Sep > 03 > Steering Shudder on Low Speed Turns or When Stopped > Page 7442 NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 8. Reprogram the PCM to the latest level available. (Does not apply to 2003-2004 vehicles) 9. Test drive to verify repair. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PCM Calibration Information Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Valve: > 03-19-12 > Sep > 03 > Steering Shudder on Low Speed Turns or When Stopped > Page 7443 SUPERSEDES: 01-25-1 WARRANTY STATUS: Eligible Under Provisions Of The New Vehicle Limited Warranty. OPERATION DESCRIPTION TIME 031912A Replace Power Steering 2.4 Hrs. Pump, P/S Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport 031912B Replace Power Steering 2.5 Hrs. Pump, P/S Cooler, Install No Hole Check Valve, Bleed P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S System A Second Time) Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport 031912C Replace Power Steering 1.6 Hrs. Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac 031912D Replace Power Steering 1.8 Hrs. Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S System A Second Time) Vehicles Built After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac 031912E Replace Power Steering 1.9 Hrs. Pump, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4X4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport 031912F Replace Power Steering 2.0 Hrs. Pump, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built After 11-07-01 But Before Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Valve: > 03-19-12 > Sep > 03 > Steering Shudder on Low Speed Turns or When Stopped > Page 7444 8-19-02 4x4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport 031912G Bleed Air From P/S 1.1 Hrs. System, And Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac 031912H Bleed Air From P/S 1.2 Hrs. System, And Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac 031912I Replace Power Steering 1.4 Hrs. Pump, Bleed Air From P/S System Vehicles 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912J Replace Power Steering 1.8 Hrs. Pump, Bleed Air From P/S System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912K Bleed Air From P/S 0.6 Hrs. System, Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912L Bleed Air From P/S 1.0 Hrs. System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport DEALER CODING CONDITION BASIC PART NO. CODE 3A674 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped Power Steering Valve: All Technical Service Bulletins Steering - Shudder on Low Speed Turns or When Stopped Article No. 03-19-12 09/29/03 ^ STEERING - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS OR AT STOP ^ VIBRATION - STEERING SHUDDER - FELT WHEN TURNING - DRIVING AT SLOW SPEEDS OR AT STOP FORD: 2001-2003 EXPLORER SPORT 2001-2004 EXPLORER SPORT TRAC This article supersedes TSB 01-25-01 to update the part numbers and the vehicle coverage. ISSUE Some 2001-2004 Explorer Sport Trac and 2001-2003 Explorer Sport vehicles may exhibit a steering wheel shudder during low-speed turning maneuvers. This may be due to the interaction between the tire and the road surface, which is amplified by the steering system. The condition will vary according to ambient temperature, road surface friction, and steering wheel turning speed. ACTION As design changes have taken place in the steering system, it is important to note the vehicle build date and follow the appropriate steps outlined in the following Service Procedure. Per the vehicle build date it may be necessary to replace the power steering pump and cooler, and install a no-hole check valve in the steering gear. Perform a thorough evacuation of air from the power steering system after replacement/installation of parts and reprogram the Powertrain Control Module (PCM) to the latest level calibration. NOTE THE STEERING SHUDDER WILL NOT BE CORRECTED UNLESS THE SYSTEM IS PURGED OF AIR WITH A VACUUM AT THE RESERVOIR. CORRECTLY FOLLOWING THE EVACUATION PROCEDURE DETAILED BELOW WILL REDUCE THE AMOUNT OF TIME NEEDED TO CORRECT THE SHUDDER. THE SHUDDER MAY STILL BE PRESENT AFTER REPLACEMENT OF THE PARTS IF THE EVACUATION PROCEDURE IS NOT PROPERLY FOLLOWED. NOTE PRIOR TO PERFORMING THIS PROCEDURE, PERFORM THE DIAGNOSIS AND TESTING DESCRIBED IN THE APPROPRIATE WORKSHOP MANUAL, SECTION 211-00 TO CONFIRM THAT ALL OTHER SYSTEM ISSUES HAVE BEEN IDENTIFIED AND RESOLVED. SERVICE PROCEDURE VEHICLES BUILT PRIOR TO APRIL 18, 2001 1. Replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. NOTE DO NOT FILL, PURGE, OR LEAK CHECK THE SYSTEM AT THIS POINT SINCE THE STEERING GEAR CHECK VALVE AND COOLER MUST ALSO BE REPLACED. 2. Replace the Cooler Assembly with service part F77Z-30746-GA. (This new cooler has a larger fin pack to maintain lower fluid temperatures). BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the return line on the new cooler to be installed and connect this new fin pack assembly to the existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section 211-02 for complete replacement instructions. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7450 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP. TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL-211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. 4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole Check Valve (E60Z-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the No-Hole Check Valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7451 5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. 6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 8. Recheck the fluid level and, if necessary, refill. 9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 11. Reprogram the PCM to the latest level available. 12. Test drive to verify repair. VEHICLES BUILT AFTER APRIL 18, 2001, BUT PRIOR TO NOVEMBER 7, 2001 1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump (Part Number 1L2Z-3A674-GA) and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. 2. Replace the Cooler Assembly with service part F77Z-3D746-GA. (This new cooler has a larger fin pack to maintain lower fluid temperatures). BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. The existing cooler return line (hose attached to the gear outlet port) will be reused to ease installation. Attach a clamp to the cooler return line to reduce fluid spillage during removal of the cooler. Disconnect the existing cooler fin pack from the cooler return line by releasing the constant tension clamp. Remove the return line on the new cooler to be installed and connect this new fin pack assembly to the existing return line. Re-secure the constant tension clamp. Refer to the Workshop Manual, Section 211-02 for complete replacement instructions. 3. Disconnect the power steering pressure line from the gear pressure port to allow replacement of the check valve. DO NOT ATTACH A CLAMP TO THE POWER STEERING PRESSURE HOSE AS IT MAY CAUSE DAMAGE TO THE TUNING CABLE INSIDE THE HOSE. Attach a clamp to the COOLER RETURN LINE to reduce fluid flow out of the gear during removal of the pressure line. Loosen the nut securing the power steering pressure hose to the gear inlet and detach it from the gear. REPLACE THE 0-RING (388897-S) ON THE POWER STEERING PRESSURE HOSE NUT. USE ROTUNDA TOOL 211-D-027 OR EQUIVALENT TO SIZE THE 0-RING. ANY OTHER METHOD OF INSTALLATION WILL DEFORM IT, MAKING IT INEFFECTIVE. 4. Replace the check valve located in the steering gear pressure side inlet port with a No-Hole Check Valve (E6DZ-3N603-A). This new check valve has a spring-loaded closure allowing flow in only one direction, without the bleeder hole that is present in the current check valve. CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Using a pick tool, remove the clip retaining the check valve in the gear inlet. Then, using the pick, remove the check valve from the port. Install the no-hole check valve WITH THE OPEN SIDE DOWNWARD into the pressure side inlet of gear (Figure 1 and Figure 2). Reattach the power steering pressure hose to the inlet of the steering gear. 5. Fill the power steering reservoir with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7452 6. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 7. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 8. Recheck the fluid level and, if necessary, refill. 9. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 10. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 11. Reprogram the PCM to the latest level available. 12. Test drive to verify repair. VEHICLES BUILT AFTER NOVEMBER 7, 2001 WARNING DO NOT INSTALL THE CHECK VALVE ON VEHICLES BUILT AFTER 11/07/2001. TRYING TO INSTALL THE CHECK VALVE WILL CAUSE DAMAGE TO THE RACK AND IT WILL HAVE TO BE REPLACED. 1. All 4X2 Sport Trac vehicles built after 4/18/2001 should omit this step and begin with Step 2 below, as these vehicles are production equipped with a high output displacement pump and do not require a pump update. All 4X4 and 4X2 Sport vehicles and 4X4 Sport Trac vehicles should replace the Power Steering Pump with a new high displacement pump Part Number 3L2Z-3A674-CARM. BEFORE REPLACEMENT, CLEAN ALL AREAS WHERE DIRT INGESTION COULD OCCUR. FAILURE TO DO SO MAY RESULT IN SYSTEM CONTAMINATION AND NOISE. Refer to the Workshop Manual, Section 211-02 for replacement instructions. 2. Check and fill the power steering reservoir as necessary with MERCON' Multi-Purpose (ATF) Transmission Fluid (XT-2-QDX) or equivalent. 3. WITH THE ENGINE OFF, apply 25 inches of vacuum to the reservoir opening. Start the engine and let idle for 1 minute. DO NOT TURN THE STEERING WHEEL. If power steering reservoir becomes low, remove the vacuum and refill. 4. WITH THE ENGINE RUNNING and NO VACUUM APPLIED TO THE SYSTEM, turn the steering wheel to the left and then to the right end-of-travel stops, KNOCKING AGAINST EACH STOP SEVERAL TIMES to purge remaining air from the steering system. Air bubbles should be seen rising from the reservoir. Use of a shop light behind the reservoir will facilitate monitoring of the release of air. Repeat this procedure four times in each direction. NOTE AT NO TIME DURING THIS PROCEDURE SHOULD THE STEERING WHEEL BE HELD ON THE STOPS OR THE POWER STEERING PUMP COULD BE DAMAGED. 5. Recheck the fluid level and, if necessary, refill. 6. Test drive the vehicle and evaluate. Perform static parking maneuvers, IDEALLY ON PAINTED CONCRETE OR SEALED ASPHALT, to evaluate the vehicle for steering shudder and any other steering concerns. 7. If steering shudder is still present, or power steering pump "whine" is occurring, a more thorough air evacuation may be needed. With 25 inches of vacuum applied, start the engine and stand outside the vehicle. Turn the steering wheel from lock-to-lock several times while watching the reservoir for bubbles (using a shop light behind the reservoir), and listen for any sign of power steering noise. When bubbles are no longer rising out of the reservoir, and any power steering system noise has ceased, shut off the engine. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7453 NOTE THIS SHOULD NOT BE OVERDONE OR IT COULD DAMAGE THE PUMP. 8. Reprogram the PCM to the latest level available. (Does not apply to 2003-2004 vehicles) 9. Test drive to verify repair. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PCM Calibration Information Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7454 SUPERSEDES: 01-25-1 WARRANTY STATUS: Eligible Under Provisions Of The New Vehicle Limited Warranty. OPERATION DESCRIPTION TIME 031912A Replace Power Steering 2.4 Hrs. Pump, P/S Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport 031912B Replace Power Steering 2.5 Hrs. Pump, P/S Cooler, Install No Hole Check Valve, Bleed P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S System A Second Time) Vehicles Built Prior To 4-18-01 4x4 Explorer Sport Trac And 4x2/4x4 Explorer Sport 031912C Replace Power Steering 1.6 Hrs. Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac 031912D Replace Power Steering 1.8 Hrs. Cooler, Install No Hole Check Valve, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S System A Second Time) Vehicles Built After 4-18-01 But Prior To 11-07-01 4x2 Explorer Sport Trac 031912E Replace Power Steering 1.9 Hrs. Pump, Bleed Air From P/S System, Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4X4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport 031912F Replace Power Steering 2.0 Hrs. Pump, Bleed Air From P/S System, Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built After 11-07-01 But Before Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Valve: > 03-19-12 > Sep > 03 > Steering - Shudder on Low Speed Turns or When Stopped > Page 7455 8-19-02 4x4 Explorer Sport Trac/4x2 Or 4x4 Explorer Sport 031912G Bleed Air From P/S 1.1 Hrs. System, And Reprogram PCM Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac 031912H Bleed Air From P/S 1.2 Hrs. System, And Reprogram PCM (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built After 11-07-01 But Before 8-19-02 4x2 Explorer Sport Trac 031912I Replace Power Steering 1.4 Hrs. Pump, Bleed Air From P/S System Vehicles 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912J Replace Power Steering 1.8 Hrs. Pump, Bleed Air From P/S System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912K Bleed Air From P/S 0.6 Hrs. System, Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport 031912L Bleed Air From P/S 1.0 Hrs. System, (Includes Time To Bleed Air From P/S A Second Time) Vehicles Built 8-19-02 Or After 4x4 Explorer Sport Trac, 4x2 Or 4x4 Explorer Sport DEALER CODING CONDITION BASIC PART NO. CODE 3A674 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Specifications Steering Angle Sensor: Specifications Steering Wheel Rotation Sensor Bolts .................................................................................................................................................... 1 Nm (10 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Specifications > Page 7460 Steering Angle Sensor: Service and Repair "For information regarding this component please refer to steering column service and repair" Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Specifications Steering Angle Sensor: Specifications Steering Wheel Rotation Sensor Bolts .................................................................................................................................................... 1 Nm (10 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Specifications > Page 7464 Steering Angle Sensor: Service and Repair "For information regarding this component please refer to steering column service and repair" Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Customer Safety Information Air Bag(s) Arming and Disarming: Customer Safety Information WARNING: ^ IF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS BEING SERVICED, THE SYSTEM MUST BE DEACTIVATED AND RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED. ^ THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, TURN THE IGNITION OFF AND DISCONNECT THE BATTERY GROUND CABLE, WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Customer Safety Information > Page 7470 Air Bag(s) Arming and Disarming: Technician Safety Information WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, CAUTIONS, AND NOTES AT THE BEGINNING OF THE DEACTIVATION PROCEDURE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Customer Safety Information > Page 7471 Air Bag(s) Arming and Disarming: Vehicle Damage Warnings CAUTION: ^ Do not handle the passenger air bag module by grabbing the edges of the deployment door. ^ Do not deactivate the side air bag module circuit be removing the side air bag bridge resistor from the side air bag to floor connector. ^ If the side air bag bridge resistor is removed, an open circuit fault will be generated by the Restraints Control Module (RCM). ^ If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Deactivation Procedure Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will This will reduce the risk of injury in the event of an accidental deployment. WARNING: To reduce the risk of personal injury, do not use any memory saver devices. NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood connected. WARNING: To reduce the risk of personal injury, do not use any memory saver devices. NOTE: The air bag warning lamp illuminates when the RGM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7474 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, See: Starting and Charging/Battery 7. Remove the two steering wheel back cover plugs. 8. Remove the driver air bag module retaining bolts. 9. Remove the driver air bag module. 1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7475 10. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector at the top of the steering column. 11. Open the glove compartment door past its stops to access the mounting screws. 12. Remove the two screws. 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Reaching one hand into the glove compartment opening push out on the passenger air bag module and separate it from the instrument panel. Note the wire harness routing for installation. 14. Disconnect the electrical connector and remove the passenger air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7476 15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. Vehicles without seat side air bags 16. CAUTION: Do not deactivate the side air bag module circuit be removing the side air bag bridge resistor from the side air bag to floor connector. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM). If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. Vehicles with seat side air bags and power driver seat 17. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. For additional information, See: Starting and Charging/Battery Vehicles with seat side air bags 18. Move and tilt the front seats to their highest and most forward position. Vehicles with seat side air bags and power driver seat 19. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, See: Starting and Charging/Battery Vehicles with seat side air bags 20. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector. 21. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7477 22. Remove the tie-strap and disconnect the driver seat side air bag electrical connector. 23. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. All vehicles 24. Install the RCM fuse F2.6 (7.5A without rear blower, 15A with rear blower) to the CJB and close the cover. 25. Connect the battery ground cable. For additional See: Starting and Charging/Battery Reactivation Procedure Reactivation All vehicles 1. Turn the ignition switch to OFF. 2. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For additional information, refer to the wiring Diagram Manual. 3. Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, See: Starting and Charging/Battery Vehicles with seat side air bags 4. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7478 5. Connect the driver seat side air bag electrical connector and tie-strap the wire harness. 6. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical connector. 7. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. Vehicles with seat side air bags and power driver seat 8. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. For additional information, See: Starting and Charging/Battery Vehicles with seat side air bags 9. Position the front seats rearward. Vehicles with seat side air bags and power driver seat 10. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, refer to See: Starting and Charging/Battery All vehicles Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7479 11. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. 12. Position the passenger air bag module to the instrument panel (I/P) and connect the electrical connector. 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Position the passenger air bag module into the instrument panel. Route the wire harness as noted in removal. 14. Install the two screws. 15. Close the glove compartment door. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7480 16. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector at the top of the steering column. 17. Position the driver air bag module to the steering wheel. 1. Connect the driver air bag module electrical connector. 2. Position the driver air bag module to the steering wheel. 18. Install the two driver air bag module retaining bolts. 19. Install the two steering wheel back cover plugs. 20. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 21. Turn the ignition switch from OFF to ON. 22. Install the RCM fuse F2.6 (7.5A without rear blower, 15A with rear blower) to the CJB and close the cover. 23. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7481 Connect the battery ground cable. 24. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: -fail to light. -remain lit continuously. -flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. 25. Clear all continuous DTCs from the restraints control module using a scan tool. Seats Removed There are two deactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. WARNING: IF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS BEING SERVICED, THE SYSTEM MUST BE DEACTIVATED AND RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED. THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. NOTE: ^ Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Disconnect the battery ground cable. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the driver air bag module. 4. Attach a Restraint System Diagnostic Tool 418-F088 (105-R0012) to the clockspring side of the driver air bag module connector. 5. Remove the passenger air bag module. 6. Attach a Restraint System Diagnostic Tool 418-F088 (105-R0012) to the vehicle harness side of the passenger air bag connector. 7. If equipped with a front power driver seat, reconnect the battery ground cable. 8. Move and tilt the front seats to their highest and most forward position. 9. If equipped with a front power driver seat, disconnect the battery ground cable. 10. Remove the affected front seat(s). 11. Disconnect the passenger seat side air bag module electrical connector (if necessary) and attach Restraint System Diagnostic Tool 418-133 (40-009) to the vehicle harness side of the passenger seat side air bag module electrical connector. 12. Disconnect the driver seat side air bag module electrical connector (if necessary) and attach Restraint System Diagnostic Tool 418-133 (40-009) to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7482 the vehicle harness side of the driver seat side air bag module electrical connector. 13. Reconnect the battery ground cable. Seats Not Removed There are two deactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. WARNING: IF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS BEING SERVICED, THE SYSTEM MUST BE DEACTIVATED AND RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED. THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. NOTE: ^ Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Disconnect the battery ground cable. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the driver air bag module. 4. Attach a Restraint System Diagnostic Tool 418-F088 (105-R0012) to the clockspring side of the driver air bag module connector. 5. Remove the passenger air bag module. 6. Attach a Restraint System Diagnostic Tool 418-F088 (105-R0012) to the vehicle harness side of the passenger air bag connector. 7. If equipped with seat side air bags and a front power driver seat reconnect the battery ground cable. 8. Move and tilt the front seats to their highest and most forward position. 9. If equipped with seat side air bags and a front power driver seat, disconnect the battery ground cable. 10. If equipped with seat side air bags, disconnect the passenger seat side air bag module electrical connector and attach Restraint System Diagnostic Tool 418-133 (40-009) to the vehicle harness side of the passenger seat side air bag module electrical connector. CAUTION: Vehicles without side air bags, do not deactivate the side air bag module circuit by removing the side air bag bridge resistor from the side air bag floor connector. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM). If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. 11. If equipped with seat side air bags, disconnect the driver seat side air bag module electrical connector and attach Restraint System Diagnostic Tool 418-133 (40-009) to the vehicle harness side of the driver seat side air bag module electrical connector. CAUTION: Vehicles without side air bags, do not deactivate the side air bag module circuit by removing the side air bag bridge resistor from the side air bag floor connector. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7483 If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. 12. Reconnect the battery ground cable. Seats Removed There are two reactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES AND PRETENSIONERS MUST BE RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. 1. Move and tilt the front seats to their highest and most forward position. 2. Disconnect the battery ground cable. 3. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 4. Remove the restraint system diagnostic tool from the driver seat side air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. Remove the restraint system diagnostic tool from the passenger seat side air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 6. Install the affected front seat(s). 7. Connect the driver seat side air bag module electrical connectors. 8. Connect the passenger seat side air bag module electrical connectors. 9. If equipped with a front power driver seat, reconnect the battery ground cable. 10. Move the front seats rearward. 11. If equipped with a front power driver seat, disconnect the battery ground cable. 12. Remove the restraint system diagnostic tool from the passenger air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 13. Install the passenger air bag module. 14. Remove the restraint system diagnostic tool from the clockspring connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 15. Install the driver air bag module. 16. Reconnect the battery ground cable. 17. Prove out the system. Seats Not Removed There are two reactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES AND Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7484 PRETENSIONERS MUST BE RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. 1. If equipped with seat side air bags, move and tilt the front seats to their highest and most forward position. 2. Disconnect the battery ground cable. 3. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 4. If equipped with seat side air bags: 1 Remove the restraint system diagnostic tool from the driver seat side air bag module electrical connector. 2 Remove the restraint system diagnostic tool from the passenger seat side air bag module electrical connector. 3 Connect the driver seat side air bag module electrical connectors. 4 Connect the passenger seat side air bag module electrical connectors. 5 Reconnect the battery ground cable. 6 Move the front seats rearward. 7 Disconnect the battery ground cable. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. Remove the restraint system diagnostic tool from the passenger air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 6. Install the passenger air bag module. 7. Remove the restraint system diagnostic tool from the clockspring connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 8. Install the driver air bag module. 9. Reconnect the battery ground cable. 10. Prove out the system. Procedures For Repair Operations SPECIAL TOOL(S) DEACTIVATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7485 INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the air bag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the seat side air bag (if equipped) and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Remove the retaining screws and position the hood release handle out of the way. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7486 3. Remove the lower steering column opening finish panel. 1 Remove the two retaining screws from the lower steering column opening finish panel. 2 Pull out to release the retaining clips and remove the lower steering column opening finish panel. 4. Remove the bolts and the lower steering column opening finish panel reinforcement. 5. Disconnect the clockspring electrical connector at the base of the steering column. 6. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7487 7. Open the glove compartment door past its stops to access the mounting screws. 8. Remove the two screws. 9. Reaching one hand into the glove compartment opening, push out on the passenger air bag module and separate it from the instrument panel. Note the wire harness routing for installation. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. 10. Disconnect the electrical connector and remove the passenger air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7488 11. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. Vehicles without seat side air bags 12. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the Restraints Control Module (RCM). If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. CAUTION: Do not deactivate the side air bag module circuit be removing the side air bag bridge resistor from the side air bag to floor connector. Vehicles with seat side air bags and power driver seat 13. Connect the battery ground cable. Vehicles with seat side air bags 14. Move and tilt the front seats to their highest and most forward position. Vehicles with seat side air bags and power driver seat 15. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Vehicles with seat side air bags 16. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7489 17. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. 18. Remove the tie-strap and disconnect the driver seat side air bag electrical connector. 19. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. All vehicles 20. Connect the battery ground cable. 21. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). See: Prove Out Procedure 22. Disconnect the battery ground cable and wait at least one minute. REACTIVATION WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, CAUTIONS, AND NOTES AT THE BEGINNING OF THE DEACTIVATION PROCEDURE. Vehicles with seat side air bags Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7490 1. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical connector. NOTE: Make sure the battery ground cable is still disconnected before proceeding with the reactivation portion of this procedure. 2. Connect the driver seat side air bag electrical connector and tie-strap the wire harness. 3. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical connector. 4. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. Vehicles with seat side air bags and power driver seat 5. Connect the battery ground cable. Vehicles with seat side air bags 6. Position the front seats rearward. Vehicles with seat side air bags and power driver seat Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7491 7. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). All vehicles 8. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. 9. Position the passenger air bag module to the Instrument Panel (I/P) and connect the electrical connector. 10. Position the passenger air bag module into the instrument panel. Route the wire harness as noted in removal. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7492 11. In stall the two screws. 12. Close the glove compartment door. 13. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector at the base of the steering column. 14. Connect the clockspring electrical connector at the base of the steering column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7493 15. Position the lower steering column opening finish panel reinforcement and install the bolts. 16. Install the lower steering column opening finish panel. 1 Position the lower steering column opening finish panel to the I/P and push in at the top to seat the retaining clips. 2 Install the screws. 17. Position the hood release handle and install the screws. 18. Connect the battery ground cable. 19. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Prove Out Procedure WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 20. Check the active restraint system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7494 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag modules connected? 3. Is the Restraints Control Module (RCM) connected? 4. Is the vehicle battery connected? Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7495 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure Turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator with the air bag modules or restraint system diagnostic tools installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag Supplemental Restraint System (SRS) fault is present, the air bag indicator will either: ^ fail to light. ^ remain lit continuously. ^ flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the RUN position. This is the time required for the Restraints Control Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Page 7496 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications Steering Gear: Specifications Power Steering Gear Turning Effort ....................................................................................................................................... ..................................................... 4 kg (10 lbs.) Turns Lock-To-Lock ................................................. ............................................................................................................................................ 3.2 - 4.0 Power Steering Purge Vacuum ............................................................................................................................................ 68 - 85 kPa (20 - 25 inch Hg) Steering Gear To Crossmember Stud Bolts And Nuts ...................................................................................................................... 200 Nm (118 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Locations > Steering Gear Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Locations > Steering Gear > Page 7502 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Locations > Page 7503 Steering Gear: Application and ID Steering Gear Identification CAUTION: Always use the ID code when ordering service parts. The steering gear identification code is located on a tag attached to the steering gear. Explorer Sport Explorer Sport Trac Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Locations > Page 7504 Steering Gear: Service and Repair Steering Gear Special Tool(s) Removal 1. Place front wheels in the straight ahead position. Do not lock the steering column. 2. Remove the front wheel and tire assemblies. 3. Remove the radiator air deflector. 1 Remove the bolts. 2 Remove the radiator air deflector. 4. Remove the power steering cooler. 5. Loosen the LH tie-rod end jam nut. 6. Remove the cotter pins and the castellated nuts. ^ Discard the cotter pins. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Locations > Page 7505 7. CAUTION: Do not damage the tie-rod end dust boot when installing the special tool. NOTE: Remove the adapter from the ball end of the special tool. Apply a small amount of grease to the tie-rod end stud and the ball of the special tool. Using the special tool, separate the tie-rod ends from the knuckles. 8. Remove the LH tie-rod end. ^ Count and record the number of turns required to remove the tie-rod end. 9. Remove the front stabilizer bar. ^ Mark the driver side end of the stabilizer bar for correct installation. 10. Rotate the steering column shaft to access the intermediate shaft pinch bolt and remove the pinch bolt. ^ Discard the bolt. 11. Lower the vehicle. 12. Turn the steering wheel back to the straight ahead position. Turn the ignition key to the locked position. 13. Raise the vehicle. 14. CAUTION: Do not allow the steering column intermediate shaft to rotate while the shaft is disconnected from the steering gear or damage to the clockspring can result. If there is evidence that the shaft has rotated, the clockspring must be removed and recentered. Disconnect the intermediate shaft from the steering gear input shaft. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Locations > Page 7506 15. Remove the nut and disconnect the power steering lines. ^ Drain the fluid into a suitable container. ^ Install new O-ring seals. 16. Plug the ends of the fluid lines and ports in the steering gear to prevent damage and entry of dirt. 17. CAUTION: Hold the tops of the steering gear to crossmember stud bolts to avoid damaging the steering gear fluid transfer tubes. Remove the nuts. 18. Remove the stud bolts and washers. 19. Remove the steering gear to crossmember insulator bushings. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Locations > Page 7507 20. Rotate the steering gear control valve housing toward the front of the vehicle. 21. Turn the steering gear input shaft to the right until the stop is reached. 22. Move the steering gear as far to the RH side of the vehicle as possible. 23. Move the LH front wheel spindle tie-rod forward to clear the frame crossmember. 24. Remove the steering gear from the vehicle. Installation 1. NOTE: Make sure the steering gear input shaft is turned to the left until the stop is reached. NOTE: Handle the steering gear with caution to avoid damage to the fluid transfer tubes and to avoid dimples in the tie-rod boots. Turn the steering gear input shaft to the right until the stop is reached. Note the number of turns. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Locations > Page 7508 2. NOTE: Make sure the steering gear control valve housing is turned toward the front of the vehicle. Install the steering gear into the RH opening of the crossmember. 3. Move the steering gear as far to the RH side of the vehicle as possible. 4. Move the LH front wheel spindle tie-rod into the opening in the crossmember and move the steering gear into position. 5. To place the steering gear in the straight ahead position, turn the steering gear input shaft to the left by half the number of turns recorded previously. 6. Rotate the steering gear control valve housing toward the rear of the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Locations > Page 7509 7. Install the steering gear to crossmember insulator bushings as shown. ^ The large end of the metal sleeve must be positioned downward. ^ Check that the mounting surfaces on the crossmember are clean and free of foreign material. 8. Install the steering gear to crossmember washers and stud bolts. ^ The dished side of the washers face down. 9. CAUTION: Hold the tops of the steering gear to crossmember stud bolts to avoid damaging the steering gear fluid transfer tubes. Install the nuts. 10. Install the lines and clamp plate. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Locations > Page 7510 11. CAUTION: Do not allow the steering column intermediate shaft to rotate while the shaft is disconnected from the steering gear or damage to the clockspring can result. If there is evidence that the shaft has rotated, the clockspring must be removed and recentered. Connect the intermediate shaft to the steering gear input shaft. Install the pinch bolt. 12. Install the power steering fluid cooler. 13. Install the front stabilizer bar. ^ Orientate the front stabilizer bar as noted during removal. 14. Install the LH tie-rod end on the front wheel spindle tie-rod. ^ Rotate the tie-rod end the number of turns recorded during removal. 15. Connect the tie-rod ends to the steering knuckles. 1 Position the tie-rod ends on the steering knuckles. 2 Install the castellated nuts. 3 Install the new cotter pins. ^ Check that the brake dust shields are not bent and are not in contact with the outer tie-rod boot seals. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Locations > Page 7511 16. Tighten the tie-rod jam nuts. 17. Install the radiator air deflector. 1 Position the radiator air deflector. 2 Install the bolts. 18. Install the front wheel and tire assemblies. 19. Fill, purge and leak check the power steering system. 20. Check the wheel alignment. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Specifications Steering Shaft: Specifications Lower Intermediate Shaft Pinch Bolt ........................................................................................................................................................ 49 Nm (36 ft. lbs.) Intermediate Shaft To Lower Intermediate Shaft Bolt ............................................................................................................... 41 - 55 Nm (30 - 40 ft. lbs.) Upper Intermediate Shaft To Steering Column Bolt .................................................................................................................. 26 - 34 Nm (19 - 25 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Specifications > Page 7515 Steering Shaft: Service and Repair Steering Column Shaft Removal 1. CAUTION: The steering column must be in the locked position, or the lower end of the steering column is to be secured or wired in such a way as to prevent the steering column from rotating, resulting in damage to the air bag sliding contact. NOTE: Discard the upper intermediate shaft to steering column shaft bolt and the upper intermediate shaft to lower steering column shaft bolt upon removal. Do not reuse; install new bolts. Remove the bolt securing the upper intermediate shaft to the lower intermediate shaft, at the midpoint connection. Collapse the lower shaft. Discard original bolt. ^ Use a new pinch bolt. 2. Remove the bolt securing the upper intermediate shaft to the steering column assembly. Remove the intermediate shaft from inside the vehicle. Discard the original bolt. Installation 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Customer Interest for Steering Wheel: > 07-4-3 > Mar > 07 > Interior - Leather Wrapping On Steering Wheel Is Loose Steering Wheel: Customer Interest Interior - Leather Wrapping On Steering Wheel Is Loose TSB 07-4-3 03/05/07 LEATHER - WRAPPED STEERING WHEEL - LEATHER COMING LOOSE FORD: 2000-2005 Thunderbird 2000-2007 Crown Victoria, Focus, Mustang, Taurus 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1999-2003 Windstar 1999-2008 F-Super Duty 2000-2005 Excursion 2000-2007 E-Series, Expedition, Explorer, Ranger 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac 2001-2008 Escape 2004-2007 F-150, Freestar 2005-2008 Escape Hybrid 2007 Edge 2004-2007 F-650, F-750 LINCOLN: 2000-2002 Continental 2000-2006 Lincoln LS 2000-2007 Town Car 2006 Zephyr 2007 MKZ 2000-2007 Navigator 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX MERCURY: 2000-2005 Sable 2000-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 2000-2007 Mountaineer 2004-2007 Monterey 2005-2008 Mariner 2006-2008 Mariner Hybrid This article supersedes TSB 04-24-3 to update the vehicle model years. ISSUE Some vehicles equipped with leather-wrapped steering wheels may exhibit the leather coming loose from the spoke area. ACTION Apply Motorcraft Instant Gel Adhesive to re-adhere the loose leather to the wheel spoke. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE IF RE-ADHERING LEATHER TO THE FRONT SIDE OF THE STEERING WHEEL ONLY, OMIT STEPS 1 AND 6. STEERING WHEEL/AIR BAG ASSEMBLY REMOVAL IS NECESSARY ONLY WHEN REPAIRING LOOSE LEATHER ON THE BACKSIDE OF THE STEERING WHEEL. CAUTION AVOID SKIN CONTACT WITH MOTORCRAFT INSTANT GEL ADHESIVE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Customer Interest for Steering Wheel: > 07-4-3 > Mar > 07 > Interior - Leather Wrapping On Steering Wheel Is Loose > Page 7524 1. Remove the steering wheel (ONLY NECESSARY TO REPAIR BACKSIDE OF STEERING WHEEL). Refer to Workshop Manual Sections 211-04 and 501-20B. 2. Fold loose leather out of the way. 3. Apply Motorcraft Instant Gel Adhesive evenly over the wheel spoke. 4. Fold the leather back into its original position. 5. Smooth the leather tuck in for neat appearance, and apply pressure until the leather is bonded to the wheel spoke (apply pressure for at least 30 seconds). NOTE THE ADHESIVE SHOULD BE COMPLETELY SET AFTER 5 MINUTES. DO NOT PULL ON THE REPAIR AREA. 6. Reinstall steering wheel. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT070403 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 3600 33 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Wheel: > 07-4-3 > Mar > 07 > Interior - Leather Wrapping On Steering Wheel Is Loose Steering Wheel: All Technical Service Bulletins Interior - Leather Wrapping On Steering Wheel Is Loose TSB 07-4-3 03/05/07 LEATHER - WRAPPED STEERING WHEEL - LEATHER COMING LOOSE FORD: 2000-2005 Thunderbird 2000-2007 Crown Victoria, Focus, Mustang, Taurus 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1999-2003 Windstar 1999-2008 F-Super Duty 2000-2005 Excursion 2000-2007 E-Series, Expedition, Explorer, Ranger 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac 2001-2008 Escape 2004-2007 F-150, Freestar 2005-2008 Escape Hybrid 2007 Edge 2004-2007 F-650, F-750 LINCOLN: 2000-2002 Continental 2000-2006 Lincoln LS 2000-2007 Town Car 2006 Zephyr 2007 MKZ 2000-2007 Navigator 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX MERCURY: 2000-2005 Sable 2000-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 2000-2007 Mountaineer 2004-2007 Monterey 2005-2008 Mariner 2006-2008 Mariner Hybrid This article supersedes TSB 04-24-3 to update the vehicle model years. ISSUE Some vehicles equipped with leather-wrapped steering wheels may exhibit the leather coming loose from the spoke area. ACTION Apply Motorcraft Instant Gel Adhesive to re-adhere the loose leather to the wheel spoke. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE IF RE-ADHERING LEATHER TO THE FRONT SIDE OF THE STEERING WHEEL ONLY, OMIT STEPS 1 AND 6. STEERING WHEEL/AIR BAG ASSEMBLY REMOVAL IS NECESSARY ONLY WHEN REPAIRING LOOSE LEATHER ON THE BACKSIDE OF THE STEERING WHEEL. CAUTION AVOID SKIN CONTACT WITH MOTORCRAFT INSTANT GEL ADHESIVE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Wheel: > 07-4-3 > Mar > 07 > Interior - Leather Wrapping On Steering Wheel Is Loose > Page 7530 1. Remove the steering wheel (ONLY NECESSARY TO REPAIR BACKSIDE OF STEERING WHEEL). Refer to Workshop Manual Sections 211-04 and 501-20B. 2. Fold loose leather out of the way. 3. Apply Motorcraft Instant Gel Adhesive evenly over the wheel spoke. 4. Fold the leather back into its original position. 5. Smooth the leather tuck in for neat appearance, and apply pressure until the leather is bonded to the wheel spoke (apply pressure for at least 30 seconds). NOTE THE ADHESIVE SHOULD BE COMPLETELY SET AFTER 5 MINUTES. DO NOT PULL ON THE REPAIR AREA. 6. Reinstall steering wheel. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT070403 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 3600 33 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 7531 Steering Wheel: Specifications Steering Wheel Bolt ............................................................................................................................. ...................................... 41 - 46 Nm (25 - 34 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 7532 Steering Wheel: Service and Repair Wheel Special Tool(s) Removal WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be installed new, not repainted. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components, whether or not the air bag is deployed. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. NOTE: Make sure the wheels are in the straight-ahead position. 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please refer to the appropriate location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery cable and wait at least one minute. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 7533 2. Remove the retaining screws and position the hood release handle out of the way. 3. Remove the lower steering column opening finish panel. 1 Remove the two retaining screws from the lower steering column opening finish panel. 2 Pull out to release the retaining clips and remove the lower 4. Remove the bolts and the lower steering column opening finish panel reinforcement. 5. Disconnect the air bag sliding contact electrical connector at the base of the steering column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 7534 6. Attach the restraint system diagnostic tool to the vehicle harness side of the air bag sliding contact electrical connector at the base of the steering column. 7. Connect the battery ground cable. 8. With the restraint system diagnostic tool connected to the vehicle harness side of the air bag sliding contact at the base of the steering column prove out the air bag system. 9. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please refer to the appropriate location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery cable and wait at least one minute. 10. Remove the two steering wheel back cover plugs. 11. Remove the two driver air bag module retaining bolts. 12. Remove the driver air bag module. ^ Disconnect the driver air bag module electrical connector. ^ Remove the driver air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 7535 13. Disconnect the steering wheel accessory electrical connector. 14. Remove and discard the steering wheel bolt. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 7536 15. CAUTION: Removing the steering wheel without using a puller can damage the column bearings. Use the 2-Jaw Puller or Steering Wheel Puller, as appropriate, to remove the steering wheel. 16. Remove the steering wheel while routing the wires from the air bag sliding contact through the steering wheel. Installation WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the even' of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be installed new, not repainted. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components, whether or not the air bag is deployed. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. 1. Position the steering wheel while routing the wires from the air bag sliding contact through the steering wheel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 7537 2. Install a new steering wheel bolt. 3. Connect the steering wheel accessory electrical connector. 4. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Remove the restraint system diagnostic tool from the vehicle harness side of the air bag sliding contact electrical connector at the base of the steering column. 5. Connect the air bag sliding contact electrical connector at the base of the steering column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 7538 6. Connect the restraint system diagnostic tool to the air bag sliding contact electrical connector at the top of the steering column. 7. Connect the battery ground cable. 8. With the restraint system diagnostic tool connected to the air bag sliding contact electrical connector at the top of the steering column, prove out the air bag system. 9. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Please refer to the appropriate location of the front air bag sensors. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 10. Remove the restraint system diagnostic tool from the air bag sliding contact electrical connector at the top of the steering column. 11. Position the driver airbag module to the steering wheel. 1 Connect the driver air bag module electrical connector. 2 Position the driver air bag module to the steering wheel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 7539 12. Install the two driver air bag module retaining bolts. 13. Install the two steering wheel back cover plugs. 14. Position the lower steering column opening finish panel reinforcement and install the bolts. 15. Install the lower steering column opening finish panel. 1 Position the lower steering column opening finish panel to the I/P and push in at the top, seating the retaining clips. 2 Install the screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 7540 16. Position the hood release handle and install the screws. 17. Connect the battery ground cable. 18. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. With the restraint system diagnostic tool removed, prove out the air bag system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Specifications Tie Rod End: Specifications Tie-Rod End Nut .................................................................................................................................. .................................................... 70 Nm (52 ft. lbs.) Tie-Rod End To Spindle Castellated Nuts ................................................................................................................................................ 90 Nm (66 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Front Suspension Balljoint Inspection Job Aid Ball Joint: Specifications Front Suspension Balljoint Inspection Job Aid Front Lower Ball Joint Measurement .................................................................................................................................................. Between lower control arm and knuckle Deflection ............................................................................................................................................. ........................................... 0-0.032 in (0-0.8mm) Reference Diagram ............................................................................................................................. ............................................................................. A Front Upper Ball Joint Measurement .................................................................................................................................................. Between upper control arm and knuckle Deflection ............................................................................................................................................. ........................................... 0-0.008 in (0-0.2mm) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Front Suspension Balljoint Inspection Job Aid > Page 7550 Reference Diagram ............................................................................................................................. ............................................................................. C Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Front Suspension Balljoint Inspection Job Aid > Page 7551 Ball Joint: Specifications General Specifications Lower Ball Joint Nut ............................................................................................................................. ................................................. 133 Nm (98 ft. lbs.) upper Ball Joint Nut ............................................ ...................................................................................................................................... 55 Nm (41 ft. lbs.) Upper and Lower Ball Joint Radial Play .............................................................................................. ................................................................... 1/32 inch Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 7552 Ball Joint: Testing and Inspection Front Lower Ball Joint Measurement .................................................................................................................................................. Between lower control arm and knuckle Deflection ............................................................................................................................................. ........................................... 0-0.032 in (0-0.8mm) Reference Diagram ............................................................................................................................. ............................................................................. A Front Upper Ball Joint Measurement .................................................................................................................................................. Between upper control arm and knuckle Deflection ............................................................................................................................................. ........................................... 0-0.008 in (0-0.2mm) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 7553 Reference Diagram ............................................................................................................................. ............................................................................. C Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 7554 Ball Joint: Service and Repair Ball Joint-Lower Special Tool(s) Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the wheel and tire assembly. 3. CAUTION: Do not allow the disc brake caliper to hang suspended from the brake hose. Provide a suitable support. Remove the caliper support bracket bolts, then position the caliper and support bracket aside. 4. Disconnect the front anti-lock brake sensor (ABS) wire from the vehicle frame. 1. Disconnect the ABS electrical connector. 2. Unclip the front ABS wire from the vehicle frame. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 7555 5. Using a suitable jack, support the front suspension lower arm. 6. Remove the tie-rod end castellated nut. ^ Remove and discard the cotter pin and the castellated nut. 7. CAUTION: Do not use a hammer to separate the tie-rod from the wheel knuckle or damage to the wheel knuckle will result. CAUTION: Do not damage the tie-rod boot when installing the special tool. Using the special tool, separate the tie-rod end from the front wheel knuckle. 8. Remove the lower ball joint castellated nut. 1. Remove and discard the cotter pin. 2. Remove and discard the castellated nut. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 7556 9. Using the special tool, separate the front wheel knuckle from the front suspension lower arm. Then, loosely install the lower ball joint castellated nut. 10. Remove the pinch bolt and nut. 11. Remove the hand-tightened lower ball joint castellated nut, then remove the front wheel knuckle. 12. Remove the snap ring from the ball joint. Discard the snap ring. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 7557 13. Using a suitable ball joint remover tool, remove the ball joint. 14. CAUTION: Do not damage the ball joint boot when installing the special tool. NOTE: Clean and inspect the control arm ball joint bore for damage before installing a new ball joint. NOTE: Make sure the new ball joint snap ring is fully seated. To install, reverse the removal procedure. ^ Always install new castellated nuts and cotter pins. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Specifications Control Arm: Specifications Lower Arm Pivot Bolts And Nuts ......................................................................................................................................................... 200 Nm (148 ft. lbs.) Upper Arm Bolts And Nuts ................................................................................. ................................................................................... 130 Nm (96 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower Arm Control Arm: Service and Repair Lower Arm Lower Arm Special Tool(s) Special Tool(s) Removal and Installation 1. Remove the wheel and tire assembly. 2. Remove the stabilizer link nut, washer and bushing. 3. Remove the front shock absorber-to-front suspension lower arm nuts. 4. Remove the torsion bar. 5. Remove the cotter pin and the nut. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower Arm > Page 7563 6. Using special tool, separate the front suspension lower arm from the front wheel knuckle/spindle. 7. Remove the nuts, bolts and the lower arm. 1 Remove the front suspension lower arm bolts and nuts. 2 Remove the front suspension lower arm. 8. To install, reverse the removal procedure. 9. Check and, if necessary, adjust the ride height. 10. Check and, if necessary, align the front end. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower Arm > Page 7564 Control Arm: Service and Repair Upper Arm Upper Arm Removal and Installation 1. Remove the wheel and tire assembly. 2. Use a suitable jack stand to support the front suspension lower arm. 3. CAUTION: To avoid possible damage to the front wheel spindle, secure the spindle to keep it from tilting before removing the pinch bolt and nut. Remove the pinch bolt and nut from the front wheel spindle. 4. Remove the nuts, bolts and the upper arm. 5. To install, reverse the removal procedure. 6. Check, and if necessary, align the front end. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Specifications Front Cross-Member: Specifications Automatic Crossmember screws .......................................................................................................................... ...................................... 85-118 Nm (63-87 ft. lbs.) Crossmember nuts ............................................. ....................................................................................................................... 88-115 Nm (65-85 ft. lbs.) Manual Crossmember bolts ............................................................................................................................. ........................................ 53-72 Nm (39-53 ft. lbs.) Crossmember nuts ............................................. ......................................................................................................................... 53-72 Nm (39-53 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System Information > Service and Repair Rear Cross-Member: Service and Repair CROSSMEMBER - TRANSMISSION SUPPORT Materials Materials Removal and Installation 1. Raise and support the vehicle. 2. Loosen, but do not remove, the nuts retaining the transmission insulator to the crossmember. 3. Support the transmission. 4. Remove the six bolts retaining the crossmember to the frame. 5. Remove the nuts and the crossmember. 6. NOTE: Apply Threadlock 262 E2FZ-19554-B meeting Ford specification WSK-M2G351-A6 or equivalent to the transmission crossmember mounting bolts. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Specifications Steering Angle Sensor: Specifications Steering Wheel Rotation Sensor Bolts .................................................................................................................................................... 1 Nm (10 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Specifications > Page 7576 Steering Angle Sensor: Service and Repair "For information regarding this component please refer to steering column service and repair" Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Specifications Spindle: Specifications Spindle-To-Lower Ball Joint Nut ........................................................................................................................................................... 133 Nm (98 ft. lbs.) Spindle-To-Upper Ball Joint Nut .............................................................................................................................................................. 55 Nm (41 ft. lbs.) Front Wheel Spindle Tie-Rod Ball Socket ............................................................................................................................................. 120 Nm (89 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Specifications > Page 7580 Spindle: Service and Repair Wheel Spindle Special Tool(s) Special Tool(s) Removal and Installation 1. Remove the brake disc and hub. 2. Remove the front brake anti-lock sensor. ^ Remove the anti-lock sensor electrical wire from the clamp. ^ Remove the bolt and position the sensor aside. 3. Remove the cotter pin and nut. 4. Using the special tool, separate the tie-rod end from the spindle. 5. Use a suitable jack stand to support the lower arm. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Specifications > Page 7581 6. CAUTION: To avoid possible damage to the front wheel spindle, secure the spindle to keep it from tilting before removing the pinch bolt and nut. Remove the nut and pinch bolt. 7. Remove the cotter pin and nut. 8. Using the special tool, separate the ball joint and remove the spindle. 9. To install, reverse the removal procedure. ^ Install the cotter pin into the lower ball joint from outboard to inboard with the fingers bent together at a right angle. Failure to do so can cause damage to the wheel and tire assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Technical Service Bulletins > Customer Interest for Stabilizer Link: > 04-21-3 > Nov > 04 > Suspension - Rear Suspension Squeaking Noise Stabilizer Link: Customer Interest Suspension - Rear Suspension Squeaking Noise TSB 04-21-3 11/01/04 SQUEAKING NOISE FROM REAR SWAY BAR LINK FORD: 2001-2005 Explorer Sport Trac ISSUE Some 2001-2005 Explorer Sport Trac vehicles may exhibit a squeaking noise from the rear suspension, which is especially noticeable when driving over bumps. The noise may be coming from the rear stabilizer bar link bushing(s). ACTION Confirm the source of the noise by jouncing the rear of the vehicle up and down, by pushing on the rear bumper. Replace the rear stabilizer bar link(s) with revised part and attachment nut(s). Torque to new specification of 55 lb-ft (75 N.m). Refer to Workshop Manual Section 204-02. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042103A Replace One Rear 0.4 Hr. Stabilizer Bar Link 042103B Replace Both Rear 0.5 Hr. Stabilizer Bar Links DEALER CODING CONDITION BASIC PART NO. CODE 5K484 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Stabilizer Link: > 04-21-3 > Nov > 04 > Suspension - Rear Suspension Squeaking Noise Stabilizer Link: All Technical Service Bulletins Suspension - Rear Suspension Squeaking Noise TSB 04-21-3 11/01/04 SQUEAKING NOISE FROM REAR SWAY BAR LINK FORD: 2001-2005 Explorer Sport Trac ISSUE Some 2001-2005 Explorer Sport Trac vehicles may exhibit a squeaking noise from the rear suspension, which is especially noticeable when driving over bumps. The noise may be coming from the rear stabilizer bar link bushing(s). ACTION Confirm the source of the noise by jouncing the rear of the vehicle up and down, by pushing on the rear bumper. Replace the rear stabilizer bar link(s) with revised part and attachment nut(s). Torque to new specification of 55 lb-ft (75 N.m). Refer to Workshop Manual Section 204-02. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042103A Replace One Rear 0.4 Hr. Stabilizer Bar Link 042103B Replace Both Rear 0.5 Hr. Stabilizer Bar Links DEALER CODING CONDITION BASIC PART NO. CODE 5K484 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Technical Service Bulletins > Page 7596 Stabilizer Link: Specifications Front Stabilizer Bar Link Nuts ....................................................................................................................... ................................................ 25 Nm (18 ft. lbs.) Rear Stabilizer Bar-To-Link Nut ................................................................................................................... ................................................ 80 Nm (59 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Stabilizer Link: Service and Repair Front "For information regarding this component please refer to Stabilizer Bar, Sway Control service and repair" Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front > Page 7599 Stabilizer Link: Service and Repair Rear "For information regarding this component please refer to Stabilizer Bar, Sway Control service and repair" Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Shackle > Component Information > Specifications Shackle: Specifications Rear Spring Shackle Lower Bolt And Nut .............................................................................................................................................. 115 Nm (85 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications Suspension Strut / Shock Absorber: Specifications Front Shock Absorber-To-Lower Arm Nuts .................................................................................................................................................. 25 Nm (18 ft. lbs.) Rear Shock Absorber-To-Frame Nuts ........................................................................................................................................................... 23 Nm (17 ft. lbs.) Shock Absorber Lower Bolt ................................................................................... .............................................................................. 63 Nm (46 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Specifications Torsion Bar: Specifications Front Torsion Bar Cover Plate Bolts .............................................................................................................................................................. 55 Nm (41 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Specifications > Page 7610 Torsion Bar: Service and Repair Torsion Bar Special Tool(s) Removal and Installation 1. Raise and support the vehicle. 2. Remove the bolts and the torsion bar cover plate. 3. NOTE: Before relieving the torsion bar tension, measure and record the measurement of the torsion bar adjustment bolt. This measurement will be used as the preset depth for the new torsion bar adjustment bolt during installation. Make preliminary adjustment references. ^ Measure and record the length where indicated. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Specifications > Page 7611 4. Relieve the torsion bar tension. 1 Position the special tool and adapters. 2 Tighten the special tool until the torsion bar adjuster lifts off the adjustment bolt. 5. CAUTION: The torsion bar adjustment bolt is coated with dry adhesive. A new bolt must be installed if it is backed off or removed. Failure to do so can cause the adjustment bolt to loosen during operation and cause a loss of vehicle alignment. Remove the torsion bar adjustment bolt and nut. 6. Loosen the special tool until the tension is removed from the torsion bar. 7. Remove the torsion bar. 1 Mark the torsion bar and the adjuster for reference during installation. 2 Remove the torsion bar insulator. 3 Grasp the torsion bar, and pull it free from the lower arm. 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection Wheel Bearing: Testing and Inspection Wheel Bearing Inspection 1. Raise the vehicle until the tire is off the floor. 2. NOTE: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow movement of the tire and wheel assembly. Grasp each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 3. If the tire and wheel (hub) is loose on the wheel spindle or does not rotate freely, perform one of the following actions. ^ On 4x2 vehicles, adjust the front wheel bearings. ^ On 4x4 vehicles, install a new wheel hub. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation Vehicle Lifting: Description and Operation JACKING WARNING: ^ DO NOT RUN THE ENGINE WHEN JACKING THE VEHICLE. THE WHEELS CONTACTING THE GROUND COULD CAUSE THE VEHICLE TO MOVE. ^ MAKE SURE THE JACK AND JACK STANDS ARE CORRECTLY LOCATED TO PREVENT THE VEHICLE FROM FALLING. ^ A WHEEL CHOCK SHOULD BE USED TO PREVENT THE VEHICLE FROM ROLLING AND FALLING OFF THE JACK. ^ WHEN ONE OF THE REAR WHEELS IS OFF THE GROUND, THE TRANSMISSION ALONE WILL NOT PREVENT THE VEHICLE FROM MOVING OR SLIPPING OFF THE JACK, EVEN IF THE TRANSMISSION IS IN P (PARK) (AUTOMATIC TRANSMISSION) OR REVERSE (MANUAL TRANSMISSION). Jacking Points - Front Jacking Points - Front The front jacking point is a tab that extends from the lower control arm. Jacking Points - Rear The rear jacking points are located on the rear axle tube CAUTION: Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and adjoining differential housing surface can occur if a floor jack or any lifting device is allowed to contact the cover at any point where the cover joins the housing. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 7619 LIFTING Lifting Points - Front 1. The front lifting points are located underneath the number one body mount bracket. CAUTION: ^ Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and adjoining differential housing surface can occur if a floor jack or any lifting device is allowed to contact the cover at any point where the cover joins the housing. ^ Damage to the suspension, fuel tank, exhaust or steering linkage components can occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. Lifting Point - Rear 1. The rear lifting point is the bottom surface of the leaf spring front eye. CAUTION: ^ Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and adjoining differential housing surface can occur if a floor jack or any lifting device is allowed to contact the cover at any point where the cover joins the housing. ^ Damage to the suspension, fuel tank, exhaust or steering linkage components can occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement Technical Service Bulletin # 01B77 Date: 011001 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 7628 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 7629 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 7630 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 7631 Attachment I - Administrative Information OASIS OASIS must be used to determine vehicle eligibility. IMPORTANT: When an eligible vehicle is at the dealership for service, OASIS must be contacted to determine if Owner Notification Program 01B77 is open. If 01B77 is listed in OASIS as open, it is important that the vehicle is inspected for eligible tires. If the eligible vehicle is not equipped with 15-, 16-, or 17-inch Firestone Wilderness AT tires a claim must be submitted using labor operation 01B77A to close the program. If an affected vehicle does not have 01B77 open, this may indicate that a refund or tire replacement has already been processed on this vehicle. Some Ford and Lincoln Mercury vehicles not listed in the AFFECTED TIRES AND VEHICLES list may have 15-, 16-, or 17-inch Firestone Wilderness AT tires installed. These vehicles are covered under this program, but will not be active in OASIS. Contact the Special Service Support Center at 1-800-325-5621 to obtain prior approval before performing the repair or issuing a refund. This will insure that a previous repair/refund has not been performed on the vehicle. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII User Manual for claims preparation and submission information. ^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type. ^ Program code 01B77. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 7632 ^ Enter the full part number of the replacement tire with the quantity of tires replaced. Tires will be reimbursed at AtW Dealer cost + 25% (wheel weights and valve stems incl.). ^ Use the appropriate labor operation(s) from Attachment II. ^ Freight is reimbursable at actual cost in the miscellaneous expense area of the claim. NOTE: Freight is only reimbursable for rural dealers whose only means of acquiring tires is by having them shipped in via common carrier. Dealers are encouraged to arrange for shipment of 4 or more tires at a time. ^ Dealers can no longer claim tire disposal for ONP 01B77. See the "National Tire Recovery and Recycle Program". You may still claim any applicable local waste tax - enter OTHER in the expense area of the claim with the actual cost. ^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires on the diagnostic code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the space provided in the diagnostic code area, use the technician comment area to complete the data entry. RELATED DAMAGE Vehicle damage caused by a tire related failure is not covered by this program. Refer to the Warranty and Policy Manual for proper claiming procedure for vehicles covered by the Ford Bumper-to-Bumper Tire Warranty (model years 2001 and 2002). All other pre-2001 model year vehicles with alleged tire related vehicle damage should be handled through the Firestone claims process, or by referring the customers to their insurance company. Damage related to replacement of tires should be handled as described in the Warranty and Policy Manual. OWNER REFUND With the increased availability of replacement tires, it will no longer be necessary for customers to pay out-of-pocket expenses for tires. Therefore, refund requests for tires purchased after November 15, 2001 will no longer be granted. Owners will be notified of the refund expiration date and will be directed to a Ford or Mercury dealer They are directed to an authorized retailer only if the Ford or Mercury dealer cannot meet their scheduling needs or tires are not in stock. All Ford and Mercury dealers (AtW and non-AtW dealers) are required to process refunds for customers who purchase tires prior to November 15, 2001. The following rules apply to refunds for tires purchased from August 1, 2001 through November 15, 2001: Refunds will be processed for vehicles listed under "AFFECTED TIRES AND VEHICLES", and for other Ford and Lincoln Mercury vehicles that have 15-. 16-, or 17-inch Wilderness AT tires installed. ^ The customer must provide the original paid receipt (a copy of their paid receipt is acceptable on an exception basis in instances where the owner requires the original for another purpose (e.g. extended tire warranty or purchase rebate). The dealer will attach the receipt to the dealer file copy of the refund claim (see claim instructions below). ^ Dealers will be reimbursed to immediately disable tires returned for a refund (see claiming instructions for refunds and Attachment II for labor operations). ^ The tires must be purchased August 1, 2000 through November 15, 2001 to be eligible for a refund (through October 31, 2001 for 1995 and 1996 F-150 owners). ^ Customers requesting refunds for tire replacement May 22, 2001 through November 15, 2001 must provide either: NOTE: This does not apply to 1995 and 1996 F-150 customers. ^ The Firestone Wilderness AT tires that were replaced. Returned tire(s) are to be disabled by the dealership. Ford will reimburse the dealer to disable (see claim instructions below and use labor operation 01B77G). If tires are brought in for refund with the DOT codes missing dealers should not process the refund. ^ A section of the old tire(s) containing the DOT codes from each of the Firestone Wilderness AT tires that were replaced (To be cut from the Wilderness AT tires that were replaced by the outside repair facility) (use labor operation 01B77L). Dealers should deface (cut in pieces or make code unreadable) the DOT sections of the tire so they cannot be used to obtain another refund. If sections are brought in for refund with the DOT code defaced dealers should not process the refund. NOTE: The DOT Code Identification Guide has been developed to help dealers determine if the DOT sections returned to the dealership are from 15-, 16-, Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 7633 or 17-inch Firestone Wilderness AT tires. Use the DOT Code Identification Guide in conjunction with the bulletin section "What if the Vehicle has a Mix of Affected and Non-Affected Tires" to determine how many tires are eligible for refund. NOTE: Ford will allow customers to file for a refund (with or without tires) for tires purchased after May 22 through June 30, 2001 because customers may not have tires to turn in. Customers must provide a paid receipt indicating tire replacement before July 1, 2001 in order to process a refund without tires or DOT sections. Customers who purchase tires after June 30, 2001 must provide tires or DOT sections. Ford will reimburse customers the following amounts: ^ Tires purchased from August 1, 2000 through May 22, 2001, the actual cost as stated on their paid receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes. ^ (1995 and 1996 F-150 vehicle only) Tires purchased from August 1, 2000 through October 31, 2001, the actual cost as stated on their paid receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes. No DOT section required. ^ Tires purchased May 23, 2001 through November 15, 2001, the actual cost as stated on the receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes up to a maximum of $110 per tire for 15 inch, and $130 per tire for 16 and 17 inch tires. ^ Refunds will not be granted for tires purchased after November 15, 2001. Note: If an owner pays for the replacement of their tires after November 15, 2001, the dealer may handle on a case by case basis following the procedure in Attachment II. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 7634 CLAIMS PREPARATION FOR REFUNDS (USE THIS PROCEDURE FOR ALL REFUND REQUESTS) NOTE: Tires must be purchased prior to November 15, 2001 ^ Enter claims using DWE. ^ Refer to ACESII User Manual for claims preparation and submission information. ^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type. ^ Program code 01B77. ^ When a customer brings in their old tires and is seeking a refund, use labor operation 01B77G (disable) and 01B77L (refund administration allowance) from Attachment II. ^ If a customer brings in the old DOT codes removed from the old tires - use labor operation 01B77L only. ^ The Miscellaneous Expense Code "ADMIN" will not be accepted under this program. A labor operation 01B77L has been provided to cover administrative costs. ^ Enter REFUND in the miscellaneous area of the claim. ^ Dealers will no longer be able to claim tire disposal for ONP 01B77. See the "National Tire Recovery and Recycle Program" You may still claim any applicable local waste tax - enter OTHER in the expense area of the claim with the actual cost. ^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires in the diagnostic code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the space provided in the diagnostic code area, use the technician comment area to complete the data entry. If the tires were replaced prior to May 23, 2001 (or November 1, 2001 for 1995 and 1996 F150 customers) the DOT may not be available, in this case record the brand, make and size of the tires in the technician comments area of the claim. RENTAL CARS TAP allowances have been increased specifically for this owner notification program. Refer to Don Brunner letter. DOT REGISTRATION OF NEW TIRES Dealers are required to register the DOT number of every tire sold to meet federal tire registration requirements. Ford has established a partnership with CIMS to assist dealers in registering these DOT codes. Information is available on QCDealer.com under CIMS Tire Registration or by contacting CIMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 7635 at 330-794-9190. NON-FORD OR LINCOLN MERCURY VEHICLES WITH FIRESTONE WILDERNESS AT Non-Ford or Lincoln Mercury vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires installed by a Certified Tire Dealer (AtW or Ford Tire Program) are eligible for replacement. The repair should be submitted using a Warranty/ESP claim type form. The dealer must enter Program Code "P19", this will allow the repair to be submitted without a VIN. The causal part must be TIRE, with the actual part numbers for reimbursement at dealer cost plus 25%, and use actual time for labor reimbursement. These types of claims cannot be submitted as an Owner Notification Repair type. Attachment II - Parts and Labor Information LABOR ALLOWANCES NON-AtW DEALERS SERVICING IN-STOCK UNITS OR CUSTOMER VEHICLES NOTE: Non-Certified Tire Dealers (AtW or Ford Tire Program) who have vehicles in stock, or customer vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires must send the vehicle to a Certified Tire Dealer (AtW or Ford Tire Program), or an approved tire retailer participating in the program to have the tire replacement performed. The non-Certified Tire Dealer (AtW or Ford Tire Program) will submit a 01B77 ONP claim using the miscellaneous expense code of "SCHP" (with a dollar value of $15.00 to cover administrative costs). Do not claim the "Admin" labor operation. PARTS REQUIREMENTS Tire Ordering Information ^ Dealers are required to install only tires from the Approved Tire List for vehicles originally equipped with 15-, 16-, and 17-inch Firestone Wilderness AT tires. Dealers should immediately order replacement tires for inventory. ^ Certified Tire Dealers will order replacement tires through normal channels. ^ Dealers not authorized for the Around the Wheel Program will not participate in this recall. Dealers may call the Ford Tire Hotline 1-888-353-3251 for enrollment and program details. TIRE AVAILABILITY: All dealers should check QCDealer.com daily for updates to the approved tires list. Distributors and tire retailers will allocate tires as best they can on a daily basis. Your dealership should do the following to ensure that you are able to secure your fair allotment of these limited volumes: Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 7636 ^ Contact your Ford authorized facing distributor(s) for each tire manufacturer. ^ Contact your Ford authorized facing tire retailers for each tire manufacturer. ^ Review with these supply points the volume of tires you need to ensure you have tires ready to fill orders with every supply point. Questions not addressed by above sources should be directed to your market area team. CUSTOMER WAIT LISTS: Dealers should create a customer wait list and record: Customer name ^ Address and phone number ^ Vehicle make ^ Model year ^ Mileage ^ Tire size NOTE: Customers should be prioritized to replace oldest tires first. WAIT LIST SURVEY Please fill out the Firestone Tire Survey in the Management Report Section of QCDealer weekly. It is critical that you answer the questions as accurately as possible as the survey results will be used to help determine the level of production from the tire manufacturers. DEALER PRICE For latest prices on replacement tires, refer to the most recent Ford Motor Company Tire Price List. PROCEDURE FOR CLAIMING REFUNDS FOR TIRES PURCHASED AFTER NOVEMBER 15, 2001 The following procedure applies to tires purchased after November 15, 2001: 1. Determine if the customer should receive special consideration based on owner loyalty, special circumstance cc, etc. 2. If the customer is eligible for special consideration the dealer will call the Special Service Support Center at 1800-325-5621 to request an authorization code. 3. The Special Service Support Center representative will ask for the following: ^ Customer Name ^ VIN ^ Date of repair ^ Original copy of invoice (be prepared to fax) 4. If the customer qualifies for a refund, the Special Service Support Center will provide your dealer with an authorization code. 5. Your dealer will input a claim with the authorization code (authorization code must be included to receive payment). 6. After the dealer receives payment for the claim, the dealer will then send the refund to the customer. NOTE: If the Special Service Support Center determines that the customer does not qualify for a refund, no authorization code will be given. Any appeals must be made by the dealer to the appropriate field representative Attachment III - Technical Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 7637 AFFECTED VEHICLES: REFER TO DEALER LETTER FOR AFFECTED TIRES AND VEHICLES OVERVIEW This program details the replacement of 15-, 16-, and 17-inch Firestone Wilderness AT tires regardless of production plant. You will need to perform a DOT code inspection prior to replacing the 15, 16, or 17-inch Wilderness AT tires. NOTE: When lowering or raising an under-vehicle spare, DO NOT use power tools. Also make sure that the spare is secure under the vehicle, and not swinging loose. The spare tire winch will ratchet when the tire is completely stowed. NOTE: Radial ATX "TEMPORARY USE" spare tires are not included under this program, and should not be replaced as part of this program. NOTE: Spare tires should always be replaced with the exact same size tire; otherwise the spare tire may not store in the proper position on the vehicle. INSPECTION 1. Inspect the vehicle tires (including the spare tire) for the presence of Firestone Wilderness AT tires. 2. If Firestone Wilderness AT tires are present replace them with a suitable replacement from the "Approved Tire List". Note: There may be cases where a vehicle is equipped with 15-, 16-, or 17-inch Firestone Wilderness AT tire sizes that are not included on the Ford-approved replacement list. These tires are not original equipment (OE) and, therefore, will not have an approved tire listed. In such cases, it is recommended that the customer install the proper OE tire, or have a tire of suitable quality installed. Reference the vehicle's "Safety Certification Label" and current "Ford Motor Company Tire Price Guide" for OE or suitable replacement recommendations. 3. If only one Firestone Wilderness AT road tire is present on the vehicle, you will need to replace the opposing tire on the same axle. However, if one (1) front and one (1) rear tire are Wilderness AT you would not automatically replace all four (4) tires instead, you would replace the two (2) Wilderness AT tires and place them on the same axle. 4. Record the DOT code from each removed tire(s) on the repair order. 5. Tires that are removed from vehicles must immediately be made unusable by either cutting through the bead and DOT code with bolt cutters, or drilling a one-inch diameter hole (directly on the DOT code to make the code unreadable) in the sidewall. 6. Adjust all tires to the proper inflation pressure, and release the vehicle. For specifications, refer to the vehicle Owner's Manual or the vehicle certification label located on the driver's door opening. NOTE: Tires that are removed from vehicles under this program, and those in dealer inventory must immediately be made unusable by either cutting the bead with bolt cutters or drilling a 1" diameter hole (directly on the DOT code to make the code unreadable) in the sidewall. Defacing the DOT code will prevent the tire from being used for an additional refund request. NOTE: If the vehicle is a 4X4, and is equipped with non-Firestone Wilderness AT tires on one axle, and the replacement tires for the Firestone equipped axle causes a mismatch with the existing non-Firestone axle, the customer is responsible for the tire mismatch. If the customer refuses to purchase matching tires to correct the mismatch - the dealer should annotate the repair order to reflect the customer's decision. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01S18 > Jun > 01 > Recall - Passenger Side Tire Inspection Technical Service Bulletin # 01S18 Date: 010618 Recall - Passenger Side Tire Inspection SAFETY RECALL 01S18 Certain 2002 Explorer and Mountaineer Vehicles - Passenger Side Tires Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01S18 > Jun > 01 > Recall - Passenger Side Tire Inspection > Page 7642 Supplement # 1 - Attachment I OASIS You must use OASIS to determine if a vehicle is eligible for this recall. NOTE: Many of the vehicles affected by this program are also affected by Special Service Instruction 01T02. Please check OASIS and if applicable, complete both actions during one customer visit. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer Recall/ONP Involved Unit Listing available on QCDealer.com. Also, correct other affected vehicles identified in OASIS which are brought to your dealership. DEALER-OWNER CONTACT Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01S18 > Jun > 01 > Recall - Passenger Side Tire Inspection > Page 7643 Immediately contact any of your affected owners whose names are not on your VIN list but identified in OASIS. Give the owner a copy of the Owner Letter and schedule a service date. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ Enter information on a recall claim type. DO NOT use a Warranty Claim type. ^ Program code 01S18. ^ Enter the full part number of the replacement tire with the quantity of tires replaced. Payment will be at the same price level as tire warranty. ^ Use the appropriate Labor Operation(s) from Attachment II. ^ Tire disposal and applicable local waste tax will be reimbursed. Enter "OTHER" in the Miscellaneous Expense area of the claim with the actual cost. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs applicable to this recall, which were made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. NOTE: Before this recall was announced, some customers may have had this tire concern and were refused coverage because the damage was believed to have been caused by a road hazard. If the refund request is for tire damage that may have been caused by this cut tire condition, a refund should be approved. RENTAL VEHICLES Ford Motor Company will pay for a rental vehicle if tires need to be installed. Fuel and insurance will be at the owner's expense. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "RENTAL", plus the number of days the vehicle was used, in the Miscellaneous Expense area of the claim. Supplement # 1 - Attachment II LABOR ALLOWANCES Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01S18 > Jun > 01 > Recall - Passenger Side Tire Inspection > Page 7644 PARTS REQUIREMENTS NOTE: If the tires on the vehicle are any other brand, please contact the Special Service Support Center at 1-800-325-5621. TIRE ORDERING Ford Tire Program/Atw Dealers You must have an order number to obtain replacement tires under this program. (Do not contact the Special Service Support Center to obtain an order number.) 1. Contact the Ford Tire Hot Line at 1-888-353-3251 to obtain an order number. Be prepared to provide the following information: ^ Your name ^ Dealer P & A code 2. After you have an order number, contact your authorized tire distributor and order replacement tires. DEALERSHIPS ELIGIBLE TO REPLACE TIRES UNDER THIS PROGRAM All Ford and Lincoln Mercury dealers enrolled on the AtW or Ford Tire Program are eligible to complete tire replacements under this program. Ford dealers interested in joining the Ford Tire Program can enroll from QCDealer.com by clicking on the Tire Center and filling out the on-line enrollment form or by calling the Ford Tire Hot Line at 1-888-353-3251 for enrollment and program details. TIRE PRICING For latest prices on replacement tires, refer to the most recent Ford Motor Company Quarterly Tire Price Guide. TIRE DISPOSAL Damaged tires that are removed from vehicles must immediately be made unusable by either cutting the bead with bolt cutters or drilling a one-inch diameter hole in the sidewall. After mutilating the tire, use your normal tire disposal procedures. Supplement # 1 - Attachment III This document details the inspection of the passenger side tires for a cut or slice in the side of the tread area (side facing curb only) which may have occurred during vehicle assembly. Any tire found with a cut or slice must be replaced. INSPECTION NOTE: Only Michelin Cross Terrain, Goodyear Eagle LS and Goodyear Wrangler AP tires are included in this inspection. If the tires on the vehicle are any other brand, contact the Special Service Support Center at 1-800-325-5621 for further instruction. NOTE: If the vehicle has more than 8,000 km (5,000 miles), all four (4) road tires must be inspected because they may have been rotated. 1. Park the vehicle so the passenger side tires are accessible and you have adequate lighting for the inspection. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01S18 > Jun > 01 > Recall - Passenger Side Tire Inspection > Page 7645 2. Visually inspect the passenger side tires along the tread area on the side of the tire for a cut or slice. See Figure 1. Scuffs in the tread and/or sidewall area are acceptable and should not be a cause for concern. 3. If the vehicle has more than 8,000 km (5,000 miles), inspect all four (4) road tires (do not inspect spare). 4. Move the vehicle forward 62 cm (2 feet) so that the tire is rotated one-half revolution. 5. Inspect the tires again. 6. If any tire is found cut or sliced (which must be replaced), refer to the following Special Note before you begin to replace any tires. SPECIAL NOTE: If one or two tires are to be replaced, the tread depth of the non-replaced tires must be checked. This must be done to determine if additional tires must be replaced. TIRE DISPOSAL Tires that are removed from the vehicle must immediately be made unusable by either cutting the bead with bolt cutters or drilling a one-inch diameter hole in the sidewall. Dispose of damaged tires using your normal tire disposal method. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01S18 > Jun > 01 > Recall - Passenger Side Tire Inspection > Page 7646 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01S18 > Jun > 01 > Recall - Passenger Side Tire Inspection > Page 7647 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01S18 > Jun > 01 > Recall - Passenger Side Tire Inspection > Page 7648 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01S18 > Jun > 01 > Recall - Passenger Side Tire Inspection > Page 7649 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01S18 > Jun > 01 > Recall - Passenger Side Tire Inspection > Page 7650 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > NHTSA01V171000 > May > 01 > Recall 01V171000: Tire Defects Tires: Recalls Recall 01V171000: Tire Defects Vehicle Description: Sport utility vehicles. The right side tires may have horizontal cuts on the edge of the tread that could have occurred during vehicle assembly. Over time, the tire could fail, increasing the risk of a crash. Dealers will inspect the tires and, if any slices are found, the cut tires will be replaced. Owner notification began June 7, 2001. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment > Page 7660 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement Technical Service Bulletin # 01B77 Date: 011001 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 7665 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 7666 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 7667 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 7668 Attachment I - Administrative Information OASIS OASIS must be used to determine vehicle eligibility. IMPORTANT: When an eligible vehicle is at the dealership for service, OASIS must be contacted to determine if Owner Notification Program 01B77 is open. If 01B77 is listed in OASIS as open, it is important that the vehicle is inspected for eligible tires. If the eligible vehicle is not equipped with 15-, 16-, or 17-inch Firestone Wilderness AT tires a claim must be submitted using labor operation 01B77A to close the program. If an affected vehicle does not have 01B77 open, this may indicate that a refund or tire replacement has already been processed on this vehicle. Some Ford and Lincoln Mercury vehicles not listed in the AFFECTED TIRES AND VEHICLES list may have 15-, 16-, or 17-inch Firestone Wilderness AT tires installed. These vehicles are covered under this program, but will not be active in OASIS. Contact the Special Service Support Center at 1-800-325-5621 to obtain prior approval before performing the repair or issuing a refund. This will insure that a previous repair/refund has not been performed on the vehicle. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII User Manual for claims preparation and submission information. ^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type. ^ Program code 01B77. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 7669 ^ Enter the full part number of the replacement tire with the quantity of tires replaced. Tires will be reimbursed at AtW Dealer cost + 25% (wheel weights and valve stems incl.). ^ Use the appropriate labor operation(s) from Attachment II. ^ Freight is reimbursable at actual cost in the miscellaneous expense area of the claim. NOTE: Freight is only reimbursable for rural dealers whose only means of acquiring tires is by having them shipped in via common carrier. Dealers are encouraged to arrange for shipment of 4 or more tires at a time. ^ Dealers can no longer claim tire disposal for ONP 01B77. See the "National Tire Recovery and Recycle Program". You may still claim any applicable local waste tax - enter OTHER in the expense area of the claim with the actual cost. ^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires on the diagnostic code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the space provided in the diagnostic code area, use the technician comment area to complete the data entry. RELATED DAMAGE Vehicle damage caused by a tire related failure is not covered by this program. Refer to the Warranty and Policy Manual for proper claiming procedure for vehicles covered by the Ford Bumper-to-Bumper Tire Warranty (model years 2001 and 2002). All other pre-2001 model year vehicles with alleged tire related vehicle damage should be handled through the Firestone claims process, or by referring the customers to their insurance company. Damage related to replacement of tires should be handled as described in the Warranty and Policy Manual. OWNER REFUND With the increased availability of replacement tires, it will no longer be necessary for customers to pay out-of-pocket expenses for tires. Therefore, refund requests for tires purchased after November 15, 2001 will no longer be granted. Owners will be notified of the refund expiration date and will be directed to a Ford or Mercury dealer They are directed to an authorized retailer only if the Ford or Mercury dealer cannot meet their scheduling needs or tires are not in stock. All Ford and Mercury dealers (AtW and non-AtW dealers) are required to process refunds for customers who purchase tires prior to November 15, 2001. The following rules apply to refunds for tires purchased from August 1, 2001 through November 15, 2001: Refunds will be processed for vehicles listed under "AFFECTED TIRES AND VEHICLES", and for other Ford and Lincoln Mercury vehicles that have 15-. 16-, or 17-inch Wilderness AT tires installed. ^ The customer must provide the original paid receipt (a copy of their paid receipt is acceptable on an exception basis in instances where the owner requires the original for another purpose (e.g. extended tire warranty or purchase rebate). The dealer will attach the receipt to the dealer file copy of the refund claim (see claim instructions below). ^ Dealers will be reimbursed to immediately disable tires returned for a refund (see claiming instructions for refunds and Attachment II for labor operations). ^ The tires must be purchased August 1, 2000 through November 15, 2001 to be eligible for a refund (through October 31, 2001 for 1995 and 1996 F-150 owners). ^ Customers requesting refunds for tire replacement May 22, 2001 through November 15, 2001 must provide either: NOTE: This does not apply to 1995 and 1996 F-150 customers. ^ The Firestone Wilderness AT tires that were replaced. Returned tire(s) are to be disabled by the dealership. Ford will reimburse the dealer to disable (see claim instructions below and use labor operation 01B77G). If tires are brought in for refund with the DOT codes missing dealers should not process the refund. ^ A section of the old tire(s) containing the DOT codes from each of the Firestone Wilderness AT tires that were replaced (To be cut from the Wilderness AT tires that were replaced by the outside repair facility) (use labor operation 01B77L). Dealers should deface (cut in pieces or make code unreadable) the DOT sections of the tire so they cannot be used to obtain another refund. If sections are brought in for refund with the DOT code defaced dealers should not process the refund. NOTE: The DOT Code Identification Guide has been developed to help dealers determine if the DOT sections returned to the dealership are from 15-, 16-, Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 7670 or 17-inch Firestone Wilderness AT tires. Use the DOT Code Identification Guide in conjunction with the bulletin section "What if the Vehicle has a Mix of Affected and Non-Affected Tires" to determine how many tires are eligible for refund. NOTE: Ford will allow customers to file for a refund (with or without tires) for tires purchased after May 22 through June 30, 2001 because customers may not have tires to turn in. Customers must provide a paid receipt indicating tire replacement before July 1, 2001 in order to process a refund without tires or DOT sections. Customers who purchase tires after June 30, 2001 must provide tires or DOT sections. Ford will reimburse customers the following amounts: ^ Tires purchased from August 1, 2000 through May 22, 2001, the actual cost as stated on their paid receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes. ^ (1995 and 1996 F-150 vehicle only) Tires purchased from August 1, 2000 through October 31, 2001, the actual cost as stated on their paid receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes. No DOT section required. ^ Tires purchased May 23, 2001 through November 15, 2001, the actual cost as stated on the receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes up to a maximum of $110 per tire for 15 inch, and $130 per tire for 16 and 17 inch tires. ^ Refunds will not be granted for tires purchased after November 15, 2001. Note: If an owner pays for the replacement of their tires after November 15, 2001, the dealer may handle on a case by case basis following the procedure in Attachment II. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 7671 CLAIMS PREPARATION FOR REFUNDS (USE THIS PROCEDURE FOR ALL REFUND REQUESTS) NOTE: Tires must be purchased prior to November 15, 2001 ^ Enter claims using DWE. ^ Refer to ACESII User Manual for claims preparation and submission information. ^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type. ^ Program code 01B77. ^ When a customer brings in their old tires and is seeking a refund, use labor operation 01B77G (disable) and 01B77L (refund administration allowance) from Attachment II. ^ If a customer brings in the old DOT codes removed from the old tires - use labor operation 01B77L only. ^ The Miscellaneous Expense Code "ADMIN" will not be accepted under this program. A labor operation 01B77L has been provided to cover administrative costs. ^ Enter REFUND in the miscellaneous area of the claim. ^ Dealers will no longer be able to claim tire disposal for ONP 01B77. See the "National Tire Recovery and Recycle Program" You may still claim any applicable local waste tax - enter OTHER in the expense area of the claim with the actual cost. ^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires in the diagnostic code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the space provided in the diagnostic code area, use the technician comment area to complete the data entry. If the tires were replaced prior to May 23, 2001 (or November 1, 2001 for 1995 and 1996 F150 customers) the DOT may not be available, in this case record the brand, make and size of the tires in the technician comments area of the claim. RENTAL CARS TAP allowances have been increased specifically for this owner notification program. Refer to Don Brunner letter. DOT REGISTRATION OF NEW TIRES Dealers are required to register the DOT number of every tire sold to meet federal tire registration requirements. Ford has established a partnership with CIMS to assist dealers in registering these DOT codes. Information is available on QCDealer.com under CIMS Tire Registration or by contacting CIMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 7672 at 330-794-9190. NON-FORD OR LINCOLN MERCURY VEHICLES WITH FIRESTONE WILDERNESS AT Non-Ford or Lincoln Mercury vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires installed by a Certified Tire Dealer (AtW or Ford Tire Program) are eligible for replacement. The repair should be submitted using a Warranty/ESP claim type form. The dealer must enter Program Code "P19", this will allow the repair to be submitted without a VIN. The causal part must be TIRE, with the actual part numbers for reimbursement at dealer cost plus 25%, and use actual time for labor reimbursement. These types of claims cannot be submitted as an Owner Notification Repair type. Attachment II - Parts and Labor Information LABOR ALLOWANCES NON-AtW DEALERS SERVICING IN-STOCK UNITS OR CUSTOMER VEHICLES NOTE: Non-Certified Tire Dealers (AtW or Ford Tire Program) who have vehicles in stock, or customer vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires must send the vehicle to a Certified Tire Dealer (AtW or Ford Tire Program), or an approved tire retailer participating in the program to have the tire replacement performed. The non-Certified Tire Dealer (AtW or Ford Tire Program) will submit a 01B77 ONP claim using the miscellaneous expense code of "SCHP" (with a dollar value of $15.00 to cover administrative costs). Do not claim the "Admin" labor operation. PARTS REQUIREMENTS Tire Ordering Information ^ Dealers are required to install only tires from the Approved Tire List for vehicles originally equipped with 15-, 16-, and 17-inch Firestone Wilderness AT tires. Dealers should immediately order replacement tires for inventory. ^ Certified Tire Dealers will order replacement tires through normal channels. ^ Dealers not authorized for the Around the Wheel Program will not participate in this recall. Dealers may call the Ford Tire Hotline 1-888-353-3251 for enrollment and program details. TIRE AVAILABILITY: All dealers should check QCDealer.com daily for updates to the approved tires list. Distributors and tire retailers will allocate tires as best they can on a daily basis. Your dealership should do the following to ensure that you are able to secure your fair allotment of these limited volumes: Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 7673 ^ Contact your Ford authorized facing distributor(s) for each tire manufacturer. ^ Contact your Ford authorized facing tire retailers for each tire manufacturer. ^ Review with these supply points the volume of tires you need to ensure you have tires ready to fill orders with every supply point. Questions not addressed by above sources should be directed to your market area team. CUSTOMER WAIT LISTS: Dealers should create a customer wait list and record: Customer name ^ Address and phone number ^ Vehicle make ^ Model year ^ Mileage ^ Tire size NOTE: Customers should be prioritized to replace oldest tires first. WAIT LIST SURVEY Please fill out the Firestone Tire Survey in the Management Report Section of QCDealer weekly. It is critical that you answer the questions as accurately as possible as the survey results will be used to help determine the level of production from the tire manufacturers. DEALER PRICE For latest prices on replacement tires, refer to the most recent Ford Motor Company Tire Price List. PROCEDURE FOR CLAIMING REFUNDS FOR TIRES PURCHASED AFTER NOVEMBER 15, 2001 The following procedure applies to tires purchased after November 15, 2001: 1. Determine if the customer should receive special consideration based on owner loyalty, special circumstance cc, etc. 2. If the customer is eligible for special consideration the dealer will call the Special Service Support Center at 1800-325-5621 to request an authorization code. 3. The Special Service Support Center representative will ask for the following: ^ Customer Name ^ VIN ^ Date of repair ^ Original copy of invoice (be prepared to fax) 4. If the customer qualifies for a refund, the Special Service Support Center will provide your dealer with an authorization code. 5. Your dealer will input a claim with the authorization code (authorization code must be included to receive payment). 6. After the dealer receives payment for the claim, the dealer will then send the refund to the customer. NOTE: If the Special Service Support Center determines that the customer does not qualify for a refund, no authorization code will be given. Any appeals must be made by the dealer to the appropriate field representative Attachment III - Technical Information Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 7674 AFFECTED VEHICLES: REFER TO DEALER LETTER FOR AFFECTED TIRES AND VEHICLES OVERVIEW This program details the replacement of 15-, 16-, and 17-inch Firestone Wilderness AT tires regardless of production plant. You will need to perform a DOT code inspection prior to replacing the 15, 16, or 17-inch Wilderness AT tires. NOTE: When lowering or raising an under-vehicle spare, DO NOT use power tools. Also make sure that the spare is secure under the vehicle, and not swinging loose. The spare tire winch will ratchet when the tire is completely stowed. NOTE: Radial ATX "TEMPORARY USE" spare tires are not included under this program, and should not be replaced as part of this program. NOTE: Spare tires should always be replaced with the exact same size tire; otherwise the spare tire may not store in the proper position on the vehicle. INSPECTION 1. Inspect the vehicle tires (including the spare tire) for the presence of Firestone Wilderness AT tires. 2. If Firestone Wilderness AT tires are present replace them with a suitable replacement from the "Approved Tire List". Note: There may be cases where a vehicle is equipped with 15-, 16-, or 17-inch Firestone Wilderness AT tire sizes that are not included on the Ford-approved replacement list. These tires are not original equipment (OE) and, therefore, will not have an approved tire listed. In such cases, it is recommended that the customer install the proper OE tire, or have a tire of suitable quality installed. Reference the vehicle's "Safety Certification Label" and current "Ford Motor Company Tire Price Guide" for OE or suitable replacement recommendations. 3. If only one Firestone Wilderness AT road tire is present on the vehicle, you will need to replace the opposing tire on the same axle. However, if one (1) front and one (1) rear tire are Wilderness AT you would not automatically replace all four (4) tires instead, you would replace the two (2) Wilderness AT tires and place them on the same axle. 4. Record the DOT code from each removed tire(s) on the repair order. 5. Tires that are removed from vehicles must immediately be made unusable by either cutting through the bead and DOT code with bolt cutters, or drilling a one-inch diameter hole (directly on the DOT code to make the code unreadable) in the sidewall. 6. Adjust all tires to the proper inflation pressure, and release the vehicle. For specifications, refer to the vehicle Owner's Manual or the vehicle certification label located on the driver's door opening. NOTE: Tires that are removed from vehicles under this program, and those in dealer inventory must immediately be made unusable by either cutting the bead with bolt cutters or drilling a 1" diameter hole (directly on the DOT code to make the code unreadable) in the sidewall. Defacing the DOT code will prevent the tire from being used for an additional refund request. NOTE: If the vehicle is a 4X4, and is equipped with non-Firestone Wilderness AT tires on one axle, and the replacement tires for the Firestone equipped axle causes a mismatch with the existing non-Firestone axle, the customer is responsible for the tire mismatch. If the customer refuses to purchase matching tires to correct the mismatch - the dealer should annotate the repair order to reflect the customer's decision. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01S18 > Jun > 01 > Recall - Passenger Side Tire Inspection Technical Service Bulletin # 01S18 Date: 010618 Recall - Passenger Side Tire Inspection SAFETY RECALL 01S18 Certain 2002 Explorer and Mountaineer Vehicles - Passenger Side Tires Inspection Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01S18 > Jun > 01 > Recall - Passenger Side Tire Inspection > Page 7679 Supplement # 1 - Attachment I OASIS You must use OASIS to determine if a vehicle is eligible for this recall. NOTE: Many of the vehicles affected by this program are also affected by Special Service Instruction 01T02. Please check OASIS and if applicable, complete both actions during one customer visit. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer Recall/ONP Involved Unit Listing available on QCDealer.com. Also, correct other affected vehicles identified in OASIS which are brought to your dealership. DEALER-OWNER CONTACT Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01S18 > Jun > 01 > Recall - Passenger Side Tire Inspection > Page 7680 Immediately contact any of your affected owners whose names are not on your VIN list but identified in OASIS. Give the owner a copy of the Owner Letter and schedule a service date. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ Enter information on a recall claim type. DO NOT use a Warranty Claim type. ^ Program code 01S18. ^ Enter the full part number of the replacement tire with the quantity of tires replaced. Payment will be at the same price level as tire warranty. ^ Use the appropriate Labor Operation(s) from Attachment II. ^ Tire disposal and applicable local waste tax will be reimbursed. Enter "OTHER" in the Miscellaneous Expense area of the claim with the actual cost. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs applicable to this recall, which were made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. NOTE: Before this recall was announced, some customers may have had this tire concern and were refused coverage because the damage was believed to have been caused by a road hazard. If the refund request is for tire damage that may have been caused by this cut tire condition, a refund should be approved. RENTAL VEHICLES Ford Motor Company will pay for a rental vehicle if tires need to be installed. Fuel and insurance will be at the owner's expense. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "RENTAL", plus the number of days the vehicle was used, in the Miscellaneous Expense area of the claim. Supplement # 1 - Attachment II LABOR ALLOWANCES Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01S18 > Jun > 01 > Recall - Passenger Side Tire Inspection > Page 7681 PARTS REQUIREMENTS NOTE: If the tires on the vehicle are any other brand, please contact the Special Service Support Center at 1-800-325-5621. TIRE ORDERING Ford Tire Program/Atw Dealers You must have an order number to obtain replacement tires under this program. (Do not contact the Special Service Support Center to obtain an order number.) 1. Contact the Ford Tire Hot Line at 1-888-353-3251 to obtain an order number. Be prepared to provide the following information: ^ Your name ^ Dealer P & A code 2. After you have an order number, contact your authorized tire distributor and order replacement tires. DEALERSHIPS ELIGIBLE TO REPLACE TIRES UNDER THIS PROGRAM All Ford and Lincoln Mercury dealers enrolled on the AtW or Ford Tire Program are eligible to complete tire replacements under this program. Ford dealers interested in joining the Ford Tire Program can enroll from QCDealer.com by clicking on the Tire Center and filling out the on-line enrollment form or by calling the Ford Tire Hot Line at 1-888-353-3251 for enrollment and program details. TIRE PRICING For latest prices on replacement tires, refer to the most recent Ford Motor Company Quarterly Tire Price Guide. TIRE DISPOSAL Damaged tires that are removed from vehicles must immediately be made unusable by either cutting the bead with bolt cutters or drilling a one-inch diameter hole in the sidewall. After mutilating the tire, use your normal tire disposal procedures. Supplement # 1 - Attachment III This document details the inspection of the passenger side tires for a cut or slice in the side of the tread area (side facing curb only) which may have occurred during vehicle assembly. Any tire found with a cut or slice must be replaced. INSPECTION NOTE: Only Michelin Cross Terrain, Goodyear Eagle LS and Goodyear Wrangler AP tires are included in this inspection. If the tires on the vehicle are any other brand, contact the Special Service Support Center at 1-800-325-5621 for further instruction. NOTE: If the vehicle has more than 8,000 km (5,000 miles), all four (4) road tires must be inspected because they may have been rotated. 1. Park the vehicle so the passenger side tires are accessible and you have adequate lighting for the inspection. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01S18 > Jun > 01 > Recall - Passenger Side Tire Inspection > Page 7682 2. Visually inspect the passenger side tires along the tread area on the side of the tire for a cut or slice. See Figure 1. Scuffs in the tread and/or sidewall area are acceptable and should not be a cause for concern. 3. If the vehicle has more than 8,000 km (5,000 miles), inspect all four (4) road tires (do not inspect spare). 4. Move the vehicle forward 62 cm (2 feet) so that the tire is rotated one-half revolution. 5. Inspect the tires again. 6. If any tire is found cut or sliced (which must be replaced), refer to the following Special Note before you begin to replace any tires. SPECIAL NOTE: If one or two tires are to be replaced, the tread depth of the non-replaced tires must be checked. This must be done to determine if additional tires must be replaced. TIRE DISPOSAL Tires that are removed from the vehicle must immediately be made unusable by either cutting the bead with bolt cutters or drilling a one-inch diameter hole in the sidewall. Dispose of damaged tires using your normal tire disposal method. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01S18 > Jun > 01 > Recall - Passenger Side Tire Inspection > Page 7683 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01S18 > Jun > 01 > Recall - Passenger Side Tire Inspection > Page 7684 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01S18 > Jun > 01 > Recall - Passenger Side Tire Inspection > Page 7685 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01S18 > Jun > 01 > Recall - Passenger Side Tire Inspection > Page 7686 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01S18 > Jun > 01 > Recall - Passenger Side Tire Inspection > Page 7687 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > NHTSA01V171000 > May > 01 > Recall 01V171000: Tire Defects Tires: All Technical Service Bulletins Recall 01V171000: Tire Defects Vehicle Description: Sport utility vehicles. The right side tires may have horizontal cuts on the edge of the tread that could have occurred during vehicle assembly. Over time, the tire could fail, increasing the risk of a crash. Dealers will inspect the tires and, if any slices are found, the cut tires will be replaced. Owner notification began June 7, 2001. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment > Page 7697 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 7698 Tires: Specifications Tire Tread Depth P235/70R16 A/S .................................................................................................................................. ................................................ 9.0 mm (0.35 inch) P255/70R16 A/T .................................................. ............................................................................................................................ 110.7 mm (0.42 inch) Tire Inflation Tires ..................................................................................................................................... See safety certification sticker located on driver door jamb. Tire Runout Specifications Aluminum Max.Radial Runout .............................................................................................................................. ..................................... 1.02 mm (0.040 inch) Max. Lateral Runout ................................................... ............................................................................................................... 1.02 mm (0.040 inch) Steel Max. Radial Runout ............................................................................................................................. ..................................... 1.02 mm (0.040 inch) Max. Lateral Runout ................................................... ............................................................................................................... 1.02 mm (0.040 inch) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Road Force Measurement Equipment > Page 7703 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 7704 Wheels: Specifications Wheel Machined Aluminum ............................................................................................................................ ................................................................. (16 x 7) Maximum Balance Weight (Total Of Inner And Outer Wheel Flange) ........................................................................................ 170 grams (6.0 ounces) Wheel Offset .......................................................................................................................... ............................................................... 12 mm (0.48 inch) Wheel Bolt Circle Runout .............................................................................................................................................................. 0.25 mm (0.OO9 inch) Wheel Rim Runout Aluminum Max. Radial Runout ............................................................................................................................. ..................................... 1.28 mm (0.050 inch) Max.Lateral Runout .................................................... ............................................................................................................... 0.50 mm (0.019 inch) Steel Max.Radial Runout .............................................................................................................................. ..................................... 0.30 mm (0.010 inch) Max.Lateral Runout .................................................... ............................................................................................................... 1.02 mm (0.040 inch) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection Wheel Bearing: Testing and Inspection Wheel Bearing Inspection 1. Raise the vehicle until the tire is off the floor. 2. NOTE: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow movement of the tire and wheel assembly. Grasp each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 3. If the tire and wheel (hub) is loose on the wheel spindle or does not rotate freely, perform one of the following actions. ^ On 4x2 vehicles, adjust the front wheel bearings. ^ On 4x4 vehicles, install a new wheel hub. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Wheel Nuts .......................................................................................................................................... ................................................. 135 Nm (100 ft. lbs.) Wheel Stud And Wheel Nuts ........................... ......................................................................................................................................... 1/2-20-19 mm hex Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Wheel Fastener: Service and Repair Front Wheel Studs Removal 1. Remove the wheel and tire assembly. 2. CAUTION: When removing the disc brake caliper, never allow it to hang from the brake hose. Provide a suitable support. Remove the brake caliper and anchor plate as an assembly. 3. Remove the brake disc and hub as follows: 1 Remove the hub grease cap. 2 Remove the cotter pin. 3 Remove the nut retainer. 4 Remove the spindle nut. 5 Remove the front wheel outer bearing retainer washer. 6 Remove the outer front wheel bearing. 7 Remove the brake disc and hub. 4. CAUTION: Place shop towels between the pry bars and the brake disc to prevent damage to the disc surface. Using two pry bars, remove the ABS sensor ring. Discard the ABS sensor ring. 5. Using a suitable press, remove the wheel stud from the brake disc and hub. Installation Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 7713 1. Using a suitable press, install the wheel stud in the brake disc and hub. 2. CAUTION: When installing the ABS sensor ring, make sure the sensor ring is pressed on straight. Position a new ABS sensor ring on the hub. Using a cylinder with 79 mm (3.16 inch) inside diameter and 96 mm (3.84 inch) outside diameter, press the ring onto the hub until the ring seats against the shoulder in the hub. 3. Install the brake disc and hub. 1 Position the brake disc and hub. 2 Install the outer front wheel bearing. 3 Install the front wheel outer bearing retainer washer. 4 Install the spindle nut. 4. Tighten the spindle nut while rotating the brake disc and hub. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 7714 5. Loosen the spindle nut. 6. Tighten the spindle nut while rotating the brake disc and hub. 7. Install the following components: 1 Install the nut retainer. 2 Install the cotter pin. 3 Install the hub grease cap. 8. Install the caliper and anchor plate assembly. 9. Install the wheel and tire assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 7715 Wheel Fastener: Service and Repair Rear Wheel Studs Special Tool(s) Special Tools Removal CAUTION: Never use a hammer to remove the wheel stud. Damage to the axle flange, hub flange, wheel bearing or hub bearing can result. 1. Raise the vehicle and install safety stands. 2. Remove the wheel and tire assembly. 3. Remove the rear disc brake caliper, rear disc support bracket and brake disc, if so equipped. Support the rear disc brake caliper with safety wire. 4. Using the C-Frame and Screw Assembly, press the wheel stud from its seat and discard. Installation CAUTION: Never use air tools to install wheel studs. The serrations can be stripped from the stud. 1. Insert a new wheel stud in the hole in the axle flange, making sure the serrations are aligned with those made by the original wheel stud. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 7716 2. Seat new wheel studs in the axle flange. - Place four flat washers over the outside end of the wheel stud. - Thread a standard wheel nut with the flat side against the washers. - Tighten the wheel nut until the wheel stud head seats against the back side of the flange. 3. Remove the wheel nut and flatwashers. 4. Install the brake disc, rear disc support bracket and the rear disc brake caliper, if so equipped. 5. Install the wheel and tire assembly. 6. Lower the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service Precautions Accumulator HVAC: Service Precautions CAUTION: Use a back-up wrench to prevent damage to the tubes. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service Precautions > Page 7721 Accumulator HVAC: Description and Operation NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. The suction accumulator is mounted on the A/C accumulator bracket to the right of the vehicle centerline. The inlet tube of the suction accumulator attaches directly to the A/C evaporator core outlet tube and the outlet tube attaches to the A/C manifold and tube. After entering the inlet of the suction accumulator, the heavier oil-laden refrigerant contacts an internally mounted dome (which serves as an umbrella) and drips down onto the bottom of the canister. - A small diameter oil bleed hole, in the bottom of the vapor return tube, allows the accumulated heavier liquid refrigerant and oil mixture to re-enter the compressor suction line at a controlled rate. - As the heavier mixture passes through the small diameter liquid bleed hole, it has a second chance to vaporize and recirculate through the A/C compressor without causing compressor damage due to slugging. - A fine mesh screened filter fits tightly around the bottom of the vapor return tube to filter out refrigerant system contaminant particles. - A desiccant bag is mounted inside the canister to absorb any moisture which may be in the refrigerant system. - A fitting located on the top of the suction accumulator is used to attach the A/C cycling switch. A long-travel Schrader-type valve stem core is installed in the fitting so that the A/C cycling switch can be removed without discharging the A/C system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service Precautions > Page 7722 Accumulator HVAC: Service and Repair REMOVAL 1. Prepare the vehicle for suction accumulator/drier removal. 1 Disconnect the battery ground cable. 2 Recover the refrigerant. 3 Remove the air cleaner assembly. 2. Detach the speed control servo. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Position the speed control servo aside. 3. Position the coolant expansion tank/windshield washer reservoir aside. 1 Remove the screws and the nuts. 2 Position the coolant expansion tank/windshield washer reservoir aside. 4. Disconnect the A/C cycling switch electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service Precautions > Page 7723 5. Disconnect the suction accumulator/drier refrigerant lines. CAUTION: Use a back-up wrench to prevent damage to the tubes. 6. Remove the two screws and the suction accumulator/drier. INSTALLATION 1. To install, reverse the removal procedure. - If a new suction accumulator/drier is to be installed, transfer the A/C cycling switch to the new suction accumulator/drier. - If a new suction accumulator/drier is to be installed, refer to refrigerant oil addition. 2. Evacuate, leak test, and charge the A/C system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service Precautions > Page 7724 Accumulator HVAC: Tools and Equipment Spring Lock Coupling Disconnect Tool Set Spring Lock Coupling Disconnect Tool Set Disconnect Tool, Spring Lock Coupling Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Air Door Actuator / Motor: > 01-12-6 > Jun > 01 > A/C Blend Door Actuator Clicking Noise Air Door Actuator / Motor: Customer Interest A/C - Blend Door Actuator Clicking Noise Article No. 01-12-6 06/24/01 ^ CLIMATE CONTROL - CLICKING NOISE FROM TEMPERATURE BLEND DOOR ACTUATOR VEHICLES PRODUCED 11/13/2000 THROUGH 4/1/2001 ^ NOISE - CLICKING NOISE FROM CLIMATE CONTROL TEMPERATURE BLEND DOOR ACTUATOR - VEHICLES PRODUCED 11/13/2000 THROUGH 4/1/2001 FORD: 2002 EXPLORER MERCURY: 2002 MOUNTAINEER ISSUE Some vehicles equipped with the manual A/C system may exhibit a continuous clicking noise from the blend door actuator when the blower speed is set at the # 2 position and the temperature control knob is set between the 12:00 and 2:00 position. This may be caused by separate power sources to the blower motor & blend door actuator counteracting each other resulting in a clicking or fluttering noise. ACTION Verify clicking or fluttering noise from the blend door actuator. If normal diagnostics cannot pinpoint the condition. perform the following wiring harness modifications. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Locate junction box (fuse panel) under instrument panel driver side. 2. Remove 3 attaching screws from the junction box bracket. The junction box will drop down. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Air Door Actuator / Motor: > 01-12-6 > Jun > 01 > A/C Blend Door Actuator Clicking Noise > Page 7734 3. On the upper side of the junction box (relay locations), locate the 16-way green connector on the outboard side of the junction box (Figure 1). 4. Remove the green connector from the junction box. 5. Remove spacer from the engagement side of the connector. 6. Locate cavity 15 (gray/yellow wire), remove terminal from connector, and cut off terminal (Figure 2). 7. On the gray/yellow wire, strip the wire insulation away and prepare for a splice. This wire will be used later in the procedure. 8. Reinstall the spacer on the engagement end of the green connector and install connector in the junction box (Figure 1). 9. Locate the 10-way gray connector on the inboard side of the junction box (Figure 1). 10. Remove the gray connector from the junction box. 11. Locate cavity # 2, light green/purple wire (Figure 2). 12. Center splice into this wire by spreading the insulation apart. 13. Locate the gray/yellow wire from Step 7. 14. Attach the gray/yellow wire to the light green/purple wire. Crimp a wire splice onto the two wires, solder the splice and cover with electrical tape. 15. Install the gray connector in to the junction box (Figure 1). 16. Reposition the junction box under the instrument panel and reinstall the 3 attaching screws. Torque to 2.4 +/- 0.4 Nm (21 lb-in +/- 3.5 lb-in.) 17. Verify proper functionality of the manual A/C system and that the clicking/fluttering noise condition has been corrected. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011206A Perform Wiring Harness 0.5 Hr. Modifications Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Air Door Actuator / Motor: > 01-12-6 > Jun > 01 > A/C Blend Door Actuator Clicking Noise > Page 7735 DEALER CODING CONDITION BASIC PART NO. CODE 14401 42 OASIS CODES: 208000, 208999, 702000, 702300 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Door Actuator / Motor: > 01-12-6 > Jun > 01 > A/C - Blend Door Actuator Clicking Noise Air Door Actuator / Motor: All Technical Service Bulletins A/C - Blend Door Actuator Clicking Noise Article No. 01-12-6 06/24/01 ^ CLIMATE CONTROL - CLICKING NOISE FROM TEMPERATURE BLEND DOOR ACTUATOR VEHICLES PRODUCED 11/13/2000 THROUGH 4/1/2001 ^ NOISE - CLICKING NOISE FROM CLIMATE CONTROL TEMPERATURE BLEND DOOR ACTUATOR - VEHICLES PRODUCED 11/13/2000 THROUGH 4/1/2001 FORD: 2002 EXPLORER MERCURY: 2002 MOUNTAINEER ISSUE Some vehicles equipped with the manual A/C system may exhibit a continuous clicking noise from the blend door actuator when the blower speed is set at the # 2 position and the temperature control knob is set between the 12:00 and 2:00 position. This may be caused by separate power sources to the blower motor & blend door actuator counteracting each other resulting in a clicking or fluttering noise. ACTION Verify clicking or fluttering noise from the blend door actuator. If normal diagnostics cannot pinpoint the condition. perform the following wiring harness modifications. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Locate junction box (fuse panel) under instrument panel driver side. 2. Remove 3 attaching screws from the junction box bracket. The junction box will drop down. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Door Actuator / Motor: > 01-12-6 > Jun > 01 > A/C - Blend Door Actuator Clicking Noise > Page 7741 3. On the upper side of the junction box (relay locations), locate the 16-way green connector on the outboard side of the junction box (Figure 1). 4. Remove the green connector from the junction box. 5. Remove spacer from the engagement side of the connector. 6. Locate cavity 15 (gray/yellow wire), remove terminal from connector, and cut off terminal (Figure 2). 7. On the gray/yellow wire, strip the wire insulation away and prepare for a splice. This wire will be used later in the procedure. 8. Reinstall the spacer on the engagement end of the green connector and install connector in the junction box (Figure 1). 9. Locate the 10-way gray connector on the inboard side of the junction box (Figure 1). 10. Remove the gray connector from the junction box. 11. Locate cavity # 2, light green/purple wire (Figure 2). 12. Center splice into this wire by spreading the insulation apart. 13. Locate the gray/yellow wire from Step 7. 14. Attach the gray/yellow wire to the light green/purple wire. Crimp a wire splice onto the two wires, solder the splice and cover with electrical tape. 15. Install the gray connector in to the junction box (Figure 1). 16. Reposition the junction box under the instrument panel and reinstall the 3 attaching screws. Torque to 2.4 +/- 0.4 Nm (21 lb-in +/- 3.5 lb-in.) 17. Verify proper functionality of the manual A/C system and that the clicking/fluttering noise condition has been corrected. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011206A Perform Wiring Harness 0.5 Hr. Modifications Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Door Actuator / Motor: > 01-12-6 > Jun > 01 > A/C - Blend Door Actuator Clicking Noise > Page 7742 DEALER CODING CONDITION BASIC PART NO. CODE 14401 42 OASIS CODES: 208000, 208999, 702000, 702300 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Page 7743 Connector View C289 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Page 7744 Air Door Actuator / Motor: Service Precautions CAUTION: Do not attempt to bend any part of the lever. It is brittle and will break. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Page 7745 Air Door Actuator / Motor: Description and Operation A/C Electronic Blend Door Actuator The A/C electronic blend door actuator is located on the rear of the A/C evaporator housing. Its function is to move the air temperature blend doors on command from the temperature control switch. - The A/C electronic blend door actuator contains a reversible electric motor and a potentiometer. The potentiometer wiper is connected to the actuator output shaft and moves with the output shaft to indicate the position of the air temperature blend door. Vacuum Control Motors The vacuum control motors: are located on the A/C evaporator housing, A/C recirculating air duct and beater air plenum chamber. - direct system airflow to the vehicle interior as determined by the function selector switch. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > A/C Electronic Blend Door Actuator Air Door Actuator / Motor: Service and Repair A/C Electronic Blend Door Actuator REMOVAL 1. Remove the instrument panel. Refer to: " Body and Frame : Interior Trim : Dashboard/Instrument Panel : Service and Repair " See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 2. Remove the A/C electronic door actuator motor. - Remove the screws. - Disconnect the harness connector and remove the A/C electronic door actuator motor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > A/C Electronic Blend Door Actuator > Page 7748 Air Door Actuator / Motor: Service and Repair Vacuum Control Motors Panel/Floor Door REMOVAL 1. Remove the lower steering column opening finish panel. 1 Remove the screws. Detach the hood release handle. 2 Remove the two screws. 3 Pull out to release the retaining clips. Remove the lower steering column opening finish panel. 2. Remove the bolts and the lower steering column opening finish panel reinforcement. 3. Remove the two bolts and the floor console mounting bracket. 4. Remove the screws. Disconnect the vacuum hose. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > A/C Electronic Blend Door Actuator > Page 7749 5. Rotate the vacuum control motor. Disengage the lever and remove the vacuum control motor. CAUTION: Do not attempt to bend any part of the lever. It is brittle and will break. INSTALLATION 1. To install, reverse the removal procedure. Panel/Defrost Door REMOVAL 1. Disconnect the battery ground cable. 2. Remove the lower steering column opening finish panel. 1 Remove the screws. Detach the hood release handle. 2 Remove the two screws. 3 pull out to release the retaining clips. Remove the lower steering column opening finish panel. 3. Remove the bolts and the lower steering column opening finish panel reinforcement. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > A/C Electronic Blend Door Actuator > Page 7750 4. Remove the two screws. Detach the relay panel. 5. Remove the screws. Disconnect the vacuum hose. 6. Rotate the vacuum control motor. Disengage the lever and remove the vacuum control motor. CAUTION: Do not attempt to bend any part of the lever. It is brittle and will break. INSTALLATION 1. To install, reverse the removal procedure. Recirculation Air Duct REMOVAL 1. Release the stops and lower the glove compartment door to the floor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > A/C Electronic Blend Door Actuator > Page 7751 2. Remove the screws and disconnect the vacuum hose. 3. Rotate the vacuum control motor, disengage the lever, and remove the vacuum control motor. CAUTION: Do not attempt to bend any part of the lever. It is brittle and will break. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Floor Duct Air Duct: Service and Repair Floor Duct REMOVAL 1. Remove the second row climate control assembly. 2. Remove the screws and the rear floor duct. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Floor Duct > Page 7756 Air Duct: Service and Repair Windshield Defroster and Side Window Demister Nozzle REMOVAL 1. Remove the instrument panel. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Removal and Installation, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 2. Remove the two screws and remove the LH demister nozzle and duct. 3. Remove the two screws and remove the RH demister nozzle and duct. 4. Remove the screws and remove the windshield defroster hose nozzle. INSTALLATION Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Floor Duct > Page 7757 1. Follow the removal procedure in reverse order. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Center Registers Air Register: Service and Repair Center Registers REMOVAL 1. Remove the audio unit. 2. Remove the screws. Disengage the spring clips. Detach the instrument panel finish panel. 3. Disconnect the cigar lighter electrical connectors. 4. Disconnect the electrical connectors. Remove the instrument panel finish panel. NOTE: The number and location of the electrical connectors will vary dependent on vehicle equipment. 5. Release the eight clips. Remove the center instrument panel register from the instrument panel finish panel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Center Registers > Page 7762 INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Center Registers > Page 7763 Air Register: Service and Repair LH Register REMOVAL 1. Remove the LH instrument panel finish panel. 2. Remove the LH instrument panel register. 1 Remove the screws. 2 Remove the LH instrument panel register. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Center Registers > Page 7764 Air Register: Service and Repair RH Register REMOVAL 1. Lift the edge of the RH instrument panel register to expose the retainers. 2. Release the retainers and remove the RH instrument panel register. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations View 151-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 7768 Connector View C132 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Heater Blower Motor Connector View C1031 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Heater Blower Motor > Page 7773 Connector View C3002 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 7774 Blower Motor: Service Precautions CAUTION: Do not attempt to bend the second row climate control assembly arm. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 7775 Blower Motor: Description and Operation The blower motor pulls air from the air inlet and forces it into the plenum assembly where it is mixed and distributed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 7776 Blower Motor: Testing and Inspection For further information regarding this component please refer to: Heating and Air Conditioning; Testing and Inspection. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Front Blower Motor: Service and Repair Front REMOVAL 1. Prepare the vehicle for blower motor removal. 1 Disconnect the battery ground cable. 2 Remove the air cleaner assembly. 2. Detach the speed control servo. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Position the speed control servo aside. 3. Position the coolant expansion tank/windshield washer reservoir aside. 1 Remove the screws and the nuts. 2 Position the coolant expansion tank/windshield washer reservoir aside. 4. Remove the blower motor. 1 Disconnect the vent hose. 2 Disconnect the electrical connector. 3 Remove the four screws. 4 Remove the blower motor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Front > Page 7779 Blower Motor: Service and Repair Second Row REMOVAL 1. Remove the floor console. 2. Remove the coin tray. 3. Remove the screws and the console insert. 4. Remove the screw and the console lid. 5. Remove the screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Front > Page 7780 6. Open the rear cupholder. Remove the screws. 7. Remove the two screws. 8. Disengage the retaining clips. Remove the console rear finish panel. 9. Remove the screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Front > Page 7781 10. Disconnect the electrical connectors. Disengage the pin-type retainer. 11. Disconnect the air distribution door linkage from the second row climate control assembly arm. Remove the second row climate control assembly. CAUTION: Do not attempt to bend the second row climate control assembly arm. 12. Remove the screws and the console rear air distribution duct. 13. Remove the nine screws and the console liner. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Front > Page 7782 14. Remove the nuts. 15. Remove the screws. 16. Remove the two screws. 17. Disconnect the blower motor resistor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Front > Page 7783 18. Disengage the pin-type retainer. 19. Slide the console reinforcement rearward. Partially remove the blower motor and air distribution duct assembly. 20. Disconnect the blower motor electrical connector. 21. Remove the screws. Remove the blower motor assembly from the console air distribution duct. INSTALLATION Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Front > Page 7784 1. Align the blower motor assembly with the console air distribution duct. Install the screws. 2. Connect the blower motor electrical connector. 3. Position and align the studs of the blower motor and air distribution duct assembly to the console reinforcement. 4. Slide the console reinforcement forward. 5. Engage the pin-type retainer. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Front > Page 7785 6. Connect the blower motor resistor electrical connector. 7. Install the two screws. 8. Install the two screws. 9. Install the nuts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Front > Page 7786 10. Install the console liner and the nine screws. 11. Install the console rear air distribution duct and the screws. 12. Connect the air distribution door linkage to the second row climate control assembly arm. CAUTION: Do not attempt to bend the second row climate control assembly arm. 13. Connect the electrical connectors. Engage the pin-type retainer. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Front > Page 7787 14. Position the second row climate control assembly. Install the screws. 15. Align the console rear finish panel to the floor console. Engage the retaining clips. 16. Install the screws. 17. Install the screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Front > Page 7788 18. Install the screws. 19. Install the console lid and the screw. 20. Install the console insert and the screws. 21. Install the coin tray. 22. Install the floor console. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations Blower Motor Relay: Locations Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 7792 Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 7793 Connector View C1011 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 7794 Blower Motor Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 7795 Relay - Micro ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Heater Blower Motor Resistor, Front Connector View C1032 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Heater Blower Motor Resistor, Front > Page 7800 Connector View C3003 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Page 7801 Blower Motor Resistor: Description and Operation The front heater blower motor switch resistor has the following features: - The assembly is located in the engine compartment on the evaporator housing next to the blower motor assembly. - Three resistor elements are mounted on the resistor board to provide four blower motor speeds. - Depending on the heater blower motor switch position, series resistance is added or bypassed in the A/C blower motor circuit to decrease or increase A/C blower motor speed. - An overheating device (thermal limiter) will open the resistor coil circuit when the temperature reaches 121°C (250°F), interrupting the blower motor operation in all speeds except high. - The thermal limiter cannot be reset and is not serviceable. The second row heater blower motor switch resistor has the following features: - The assembly is located in the high-series flow-through floor console next to the blower motor assembly. - There is one resistor element are mounted on the resistor board to provide two blower motor speeds. - Depending on the heater blower motor switch position, series resistance is added or bypassed in the A/C blower motor circuit to decrease or increase A/C blower motor speed. - An overheating device (thermal limiter) will open the resistor coil circuit when the temperature reaches 121°C (250°F), interrupting the blower motor operation in all speeds. - The thermal limiter cannot be reset and is not serviceable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Front Blower Motor Resistor: Service and Repair Front REMOVAL 1. Prepare the vehicle for heater blower motor switch resistor removal. 1 Disconnect the battery ground cable. 2 Remove the air cleaner assembly. 2. Detach the speed control servo. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Position the speed control servo aside. 3. Position the coolant expansion tank/windshield washer reservoir aside. 1 Remove the screws and nuts. 2 Position the reservoir aside. 4. Disconnect the heater blower motor switch resistor electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Front > Page 7804 5. Remove the screws and the heater blower motor switch resistor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Front > Page 7805 Blower Motor Resistor: Service and Repair Second Row REMOVAL 1. Remove the floor console. 2. Disconnect the heater blower motor switch resistor electrical connector. 3. Remove the screws and the heater blower motor switch resistor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Description and Operation Blower Motor Switch: Description and Operation The blower motor switch controls blower motor speed by adding or by passing resistors in the heater blower motor switch resistor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and Repair Cabin Air Filter: Service and Repair NOTE: The air distribution system of this vehicle cannot be equipped with a cabin air filter. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications Compressor Clutch: Specifications Magnetic Clutch Air Gap Clearance 0.35-0.75 mm 0.014-0.030 in Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 7816 Compressor Clutch: Service Precautions CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 7817 Compressor Clutch: Description and Operation NOTE: - Internal A/C compressor components are not serviced separately. The FS-10 A/C compressor is serviced only as an assembly. The A/C clutch, A/C clutch pulley, A/C clutch field coil and the shaft seal are serviceable. - Installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. The FS-10 A/C compressor has the following characteristics: - A ten-cylinder swashplate design utilizing the tangential design mount. - A one-piece lip-type seal (replaceable from the front of the A/C compressor) is used to seal it at the shaft opening in the assembly. - Five double-acting pistons operate within the cylinder assembly. The pistons are actuated by a swashplate that changes the rotating action of the shaft to a reciprocating force. - Reed-type discharge valves are located between the cylinder assembly and the head at each end of the A/C compressor. - The A/C compressor uses PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent. This oil contains special additives required for the A/C compressor. - The A/C compressor oil from vehicles equipped with an FS-10 A/C compressor may have a dark color while maintaining a normal oil viscosity. This is normal for this A/C compressor because carbon from the piston rings will discolor the oil. The magnetic A/C clutch has the following characteristics: - It drives the compressor shaft. - When battery positive voltage (B+) is applied to the A/C clutch field coil, the A/C clutch is drawn toward the A/C clutch pulley. - The magnetic force locks the A/C clutch and the A/C clutch pulley together as one unit, causing the compressor shaft to rotate. - When B+ is removed from the A/C clutch field coil, springs in the A/C clutch move the A/C clutch away from the A/C clutch pulley. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 7818 Compressor Clutch: Adjustments 1. Check the A/C clutch air gap at three equally-spaced places between the A/C clutch hub and the A/C clutch pulley. 2. Remove the A/C clutch. Add or remove spacers between the A/C clutch and the compressor shaft until clearance is within specification. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 7819 Compressor Clutch: Service and Repair Special Tool(s) SPECIAL TOOL(S) REMOVAL 1. Remove the A/C compressor. 2. Remove the bolt. 1 Hold the A/C clutch hub with the special tool. 2 Remove the bolt. 3. Remove the A/C clutch and the A/C clutch hub spacer. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 7820 1 Thread an 8 x 1.25 mm bolt into the A/C clutch to force it from the compressor shaft. 2 Lift the A/C clutch and the A/C clutch hub spacer from the compressor shaft. 4. Remove the pulley snap ring. 5. Remove the A/C clutch pulley. 6. Remove the A/C clutch field coil. 1 Note the location of the A/C clutch field coil electrical connector. 2 Install the special tool on the nose opening of the A/C compressor. 3 Install the special tool. 4 Remove the A/C clutch field coil. CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. INSTALLATION 1. Clean the A/C clutch field coil and pulley bearing mounting surfaces. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 7821 2. Install the A/C clutch field coil. 1 Place the A/C clutch field coil on the A/C compressor with the A/C clutch field coil electrical connector correctly positioned. 2 Place the special tool on the A/C clutch field coil. 3 Place the special tool on the special tool. 4 Use the special tool to install the A/C clutch field coil until bottomed completely against the A/C compressor. CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. 3. Install the A/C clutch pulley. NOTE: The A/C clutch pulley is a tight fit on the A/C compressor head; it must be correctly aligned during installation. 4. Install the pulley snap ring with the bevel side out. 5. Place one nominal thickness A/C clutch hub spacer inside the clutch hub spline opening. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 7822 6. Install the A/C clutch. 7. Install the bolt. 1 Hold the A/C clutch hub with the special tool. 2 Tighten the bolt. 8. Measure and adjust the clutch air gap by removing or adding A/C clutch hub spacers. 9. Install the A/C compressor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 7823 Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams Connector View C100 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 7827 Compressor Clutch Coil: Service Precautions CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 7828 Compressor Clutch Coil: Service and Repair Special Tool(s) SPECIAL TOOL(S) REMOVAL 1. Remove the A/C compressor. 2. Remove the bolt. 1 Hold the A/C clutch hub with the special tool. 2 Remove the bolt. 3. Remove the A/C clutch and the A/C clutch hub spacer. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 7829 1 Thread an 8 x 1.25 mm bolt into the A/C clutch to force it from the compressor shaft. 2 Lift the A/C clutch and the A/C clutch hub spacer from the compressor shaft. 4. Remove the pulley snap ring. 5. Remove the A/C clutch pulley. 6. Remove the A/C clutch field coil. 1 Note the location of the A/C clutch field coil electrical connector. 2 Install the special tool on the nose opening of the A/C compressor. 3 Install the special tool. 4 Remove the A/C clutch field coil. CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. INSTALLATION 1. Clean the A/C clutch field coil and pulley bearing mounting surfaces. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 7830 2. Install the A/C clutch field coil. 1 Place the A/C clutch field coil on the A/C compressor with the A/C clutch field coil electrical connector correctly positioned. 2 Place the special tool on the A/C clutch field coil. 3 Place the special tool on the special tool. 4 Use the special tool to install the A/C clutch field coil until bottomed completely against the A/C compressor. CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. 3. Install the A/C clutch pulley. NOTE: The A/C clutch pulley is a tight fit on the A/C compressor head; it must be correctly aligned during installation. 4. Install the pulley snap ring with the bevel side out. 5. Place one nominal thickness A/C clutch hub spacer inside the clutch hub spline opening. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 7831 6. Install the A/C clutch. 7. Install the bolt. 1 Hold the A/C clutch hub with the special tool. 2 Tighten the bolt. 8. Measure and adjust the clutch air gap by removing or adding A/C clutch hub spacers. 9. Install the A/C compressor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 7832 Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service Precautions Compressor Shaft Seal: Service Precautions CAUTION: To prevent refrigerant system contamination, do not allow dirt or other foreign materials to enter the A/C compressor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service Precautions > Page 7836 Compressor Shaft Seal: Service and Repair SPECIAL TOOL(S) REMOVAL 1. Remove the A/C clutch from the A/C compressor. 2. Remove the shaft seal felt from the nose of the A/C compressor with the special tool. 3. Clean the compressor nose area. 4. Insert the tip of the special tool into one of the snap ring eyes. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service Precautions > Page 7837 5. Rotate the special tool to position the tool tip and the snap ring eye closest to the A/C compressor shaft. 6. Pull the special tool up quickly while keeping the tool shaft against the side of the nose opening and remove the snap ring. 7. Engage the special tool into the inside diameter of the shaft seal. 8. Turn the tool handle clockwise to expand the tool tip inside of the shaft seal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service Precautions > Page 7838 9. Pull the seal from the A/C compressor. INSTALLATION 1. Clean the A/C compressor nose area. CAUTION: To prevent refrigerant system contamination, do not allow dirt or other foreign materials to enter the A/C compressor. 2. Place the shaft seal on the special tool. Lubricate the shaft seal and the special tool with PAG oil or equivalent. 3. Position the shaft seal and the special tool over the A/C compressor shaft. 4. Push the shaft seal onto the A/C compressor shaft with the special tool until seated. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service Precautions > Page 7839 5. Install the shaft seal snap ring. 6. Carry out the A/C Compressor - External Leak Test. See: Testing and Inspection/A/C Compressor External Leak Test 7. Install the shaft seal felt. 8. Install the A/C clutch. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service Precautions > Page 7840 Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 7844 Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 7845 Connector View C1008 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 7846 Compressor Clutch Relay: Description and Operation Wide Open Throttle A/C Cut-Off The wide open throttle A/C cutoff relay (may be referred to as the A/C clutch relay) is normally open. There is no direct electrical connection between the A/C switch or EATC Module and the A/C clutch. The PCM will receive a signal indicating that A/C is requested (for some applications, this message is sent through the BUS + and BUS - circuits). When A/C is requested, the PCM will check other A/C related inputs that are available (such as ACP (SW), A/C Cycling Switch (ACCS)). If these inputs indicate A/C operation is OK, and the engine conditions are OK (such as coolant temperature, engine rpm, throttle position), the PCM will ground the Wide Open Throttle A/C (WAC) output, closing the relay contacts and sending voltage to the A/C clutch. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 7847 Compressor Clutch Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 7848 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Service and Repair Compressor Fitting HVAC: Service and Repair REMOVAL 1. Prepare the vehicle for A/C manifold and tube removal. 1 Disconnect the battery ground cable. 2 Recover the refrigerant. 3 Remove the air cleaner assembly. 4 Remove the A/C compressor. 2. Disconnect the A/C pressure cut-off switch electrical connector. 3. Disconnect the A/C manifold and tube from the A/C condenser core. Remove and discard the O-ring seal. - During installation, install a new O-ring seal lubricated with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B. 4. Disconnect the A/C manifold and tube spring lock coupling. - During installation, install new O-ring seals lubricated with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B. 5. Raise and support the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Service and Repair > Page 7852 6. Remove the bolt. Detach the A/C manifold and tube. 7. Lower the vehicle. 8. Remove the A/C manifold and tube from the vehicle. INSTALLATION 1. To install, reverse the removal procedure. - If a new A/C manifold and tube is to be installed, transfer the A/C pressure cut-off switch to the new A/C manifold and tube. 2. Evacuate, leak test, and charge the A/C system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Service and Repair > Page 7853 Compressor Fitting HVAC: Tools and Equipment Spring Lock Coupling Disconnect Tool (5/8 Inch) Disconnect Tool, Spring Lock Coupling Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Service and Repair > Page 7854 Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation Condenser HVAC: Description and Operation NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the Suction accumulator. The A/C condenser core has the following characteristics: - It is an aluminum fin and tube design heat exchanger located in front of the vehicle radiator. - It cools compressed refrigerant gas by allowing air to pass over fins and tubes to extract heat and condense refrigerant gas to liquid refrigerant as it is cooled. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation > Page 7858 Condenser HVAC: Testing and Inspection ON-VEHICLE LEAK TEST 1. Discharge and recover the refrigerant. 2. Disconnect the suspect A/C evaporator core or A/C condenser core from the A/C system. NOTE: DO NOT leak test an A/C evaporator core with the suction accumulator/drier attached to the core tubes. 3. Clean the spring lock couplings. 4. Connect the appropriate test fittings from the R-12/R-134a Air Conditioning Test Fitting Set to the evaporator or condenser tube connections. 5. Connect the red and blue hoses from the R-134a Manifold Gauge Set to the test fittings on the A/C evaporator core or A/C condenser core. Connect the yellow hose to a known good vacuum pump. NOTE: The automatic shut-off valves on some gauge set hoses do not open when connected to the test fittings. If available, use hoses without shut-off valves. If hoses with shut-off valves are used, make sure the valve opens when attached to the test fittings or install an adapter which will activate the valve. The test is not valid if the shut-off valve does not open. 6. Open both gauge set valves and start the vacuum pump. Allow the vacuum pump to operate for a minimum of 45 minutes after the gauge set low pressure gauge indicates 101 kPa (30 in-Hg). The 45 minute evacuation is necessary to remove any refrigerant from oil left in the A/C evaporator core or A/C condenser core. If the refrigerant is not completely removed from the oil, outgassing will degrade the vacuum and appear as a refrigerant leak. 7. If the low pressure gauge reading will not drop to 101 kPa (30 in-Hg) when the valves on the gauge and manifold set are open and the vacuum pump is operating, close the gauge set valves and observe the low pressure gauge. If the pressure rises rapidly to zero, a large leak is indicated. Recheck the test fitting connections and gauge set connections before installing a new A/C evaporator core or A/C condenser core. 8. After evacuating for 45 minutes, close the gauge set valves and stop the vacuum pump. Observe the low pressure gauge; it should remain at the 101 kPa (30 in-Hg) mark. If the low pressure gauge reading rises 34 or more kPa (10 or more in-Hg) of vacuum from the 101 kPa (30 in-Hg) position in 10 minutes, a leak is indicated. - If a very small leak is suspected, wait 30 minutes and observe the vacuum gauge. - If a small amount of vacuum is lost, operate the vacuum pump with gauge valves open for an additional 30 minutes to remove any remaining refrigerant from the oil in the A/C evaporator core or A/C condenser core. Then recheck for loss of vacuum. - If a very small leak is suspected, allow the system to set overnight with vacuum applied and check for vacuum loss. 9. If the A/C evaporator core or A/C condenser core does leak, as verified by the above procedure, install a new A/C evaporator core or A/C condenser core. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation > Page 7859 Condenser HVAC: Service and Repair REMOVAL NOTE: - Installation of a new suction accumulator/drier is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator/drier. - If an A/C condenser core leak is suspected, the A/C condenser core must be leak tested before it is removed from the vehicle. 1. Prepare the vehicle for A/C condenser core removal. 1 Disconnect the battery ground cable. 2 Recover the refrigerant. 3 Remove the air cleaner assembly. 2. Disconnect the A/C manifold and tube from the A/C condenser core. Remove and discard the O-ring seal. - During installation, install a new O-ring seal lubricated with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B. 3. Disconnect the condenser to evaporator tube from the A/C condenser core. Remove and discard the O-ring seal. - During installation, install a new O-ring seal lubricated with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B. 4. Raise the vehicle. 5. Remove the lower air deflector. 1 Remove the seven screws. 2 Remove the two pin-type retainers and the air deflector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation > Page 7860 6. Remove the metallic clip. Detach the transmission oil cooler lines. 7. Remove the bolt. 8. Remove the bolt and the A/C condenser core. INSTALLATION 1. To install, reverse the removal procedure. - If a new A/C condenser core is to be installed, refer to refrigerant oil addition. - If a new A/C condenser core is to be installed, a new A/C evaporator core orifice should also be installed. 2. Evacuate, leak test, and charge the A/C system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation > Page 7861 Condenser HVAC: Tools and Equipment Spring Lock Coupling Disconnect Tool Set Spring Lock Coupling Disconnect Tool Set Disconnect Tool, Spring Lock Coupling Heater Hose Disconnect Tool Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation > Page 7862 Special Tool(s) Set, A/C Fittings Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser Fan Motor Relay, HVAC > Component Information > Locations Condenser Fan Motor Relay: Locations Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 7866 Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 7867 Connector View C1056 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 7868 Condenser Fan Motor Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 7869 Relay - Micro ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Function Selector Switch Assembly, Front Control Assembly: Diagrams Function Selector Switch Assembly, Front Connector View C294a Connector View C294b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Function Selector Switch Assembly, Front > Page 7874 Connector View C294c Connector View C294d Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Function Selector Switch Assembly, Front > Page 7875 Connector View C3006 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Page 7876 Control Assembly: Service Precautions CAUTION: Do not attempt to bend the second row climate control assembly arm. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Page 7877 Control Assembly: Description and Operation Function Selector Switch The function selector switch combines a vacuum selector valve with two electrical switches to supply battery voltage (B+) to the A/C clutch circuit and the blower motor speed control circuit. Temperature Control Switch Temperature selection is accomplished with a potentiometer connected to the electric blend door. Movement of the temperature control switch from COOL (blue) to WARM (Red) causes a corresponding movement on the air temperature that the air system will maintain. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Front Control Assembly: Service and Repair Front REMOVAL 1. Remove the audio unit. 2. Remove the screws. Disengage the spring clips. Detach the instrument panel finish panel. 3. Disconnect the cigar lighter electrical connectors. 4. Disconnect the electrical connectors. Remove the instrument panel finish panel. NOTE: The number and location of the electrical connectors will vary dependent on vehicle equipment. 5. Remove the screws and the climate control assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Front > Page 7880 6. Disconnect the climate control assembly. - Disconnect the electrical connectors. - Disconnect the vacuum harness connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Front > Page 7881 Control Assembly: Service and Repair Second Row REMOVAL 1. Remove the floor console. 2. Remove the coin tray. 3. Remove the screws and the console insert. 4. Remove the screw and the console lid. 5. Remove the screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Front > Page 7882 6. Open the rear cupholder. Remove the screws. 7. Remove the two screws. 8. Disengage the retaining clips. Remove the console rear finish panel. 9. Remove the screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Front > Page 7883 10. Disconnect the electrical connectors. Disengage the pin-type retainer. 11. Disconnect the air distribution door linkage from the second row climate control assembly arm. Remove the second row climate control assembly. CAUTION: Do not attempt to bend the second row climate control assembly arm. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Front > Page 7884 Control Assembly: Service and Repair Front Climate Control Assembly Switches REMOVAL 1. Remove the climate control assembly. 2. Remove the heater blower motor switch. 1 Remove the screw. 2 Rotate and remove the heater blower motor switch. NOTE: The knob will come off when the switch is removed. 3. Remove the temperature control switch and the A/C damper door switch. 1 Remove the screw. 2 Rotate and remove the temperature control switch. 3 Rotate and remove the A/C damper door switch. NOTE: The knobs will come off when the switch is removed. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Front > Page 7885 Control Assembly: Service and Repair Front Climate Control Assembly Illumination Bulbs REMOVAL 1. Remove the climate control assembly. 2. Turn and pull the lamp socket. - Install a new the bulb in the socket. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Diagrams > Peanut Fitting Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Diagrams > Peanut Fitting > Page 7890 Spring Lock Coupling Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Diagrams > Page 7891 Coupler HVAC: Service Precautions CAUTION: - Do not use metal tools to remove the O-ring seals. They can cause axial scratches across the O-ring seal grooves, resulting in refrigerant leaks. - Do not use a screwdriver or similar tool to remove the A/C tube lock coupling spring; this can cause axial scratches across the O-ring seal grooves resulting in refrigerant leaks. - Maintain low speed drill rotation when inserting or removing the cleaning tool to prevent axial scratches which may cause future leaks. - Use only the new O-ring seals. The use of any O-ring seals other than those specified in the Ford Master Parts Catalog may result in intermittent leakage during vehicle operation. - Support the female fitting with a wrench to prevent the tubes from twisting. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Diagrams > Page 7892 Coupler HVAC: Description and Operation Spring Lock Coupling Spring Lock Coupling The spring lock coupling is a refrigerant line coupling held together by a garter spring inside a circular cage. When the coupling is connected together, the flared end of the female fitting slips behind the garter spring inside the cage of the male fitting. - The garter spring and cage then prevent the flared end of the female fitting from pulling out of the cage. - Three O-ring seals are used to seal between the two halves of the spring lock couplings. - Use only the O-ring seals listed in the Ford Master Parts Catalog for the spring lock coupling. - A plastic indicator ring may be used on the spring lock couplings of the A/C evaporator core to indicate, during vehicle assembly, that the coupling is connected. Once the coupling is connected, the indicator ring is no longer necessary but will remain captive by the coupling near the cage opening. - The indicator ring may also be used during service operations to indicate connection of the coupling. - An A/C tube lock coupling clip may be used to secure the coupling but is not required. Peanut Fitting The A/C condenser core uses the peanut shaped refrigerant fittings instead of spring lock couplings. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Diagrams > Page 7893 - The male and female blocks of the peanut fitting are retained with a nut. - An O-ring seal is installed around the tube on the male block. - The female block is welded to the tube and is not adjustable. - Support the female fitting with a wrench to prevent twisting of the tubes. - The male block will pivot around the tube to allow for alignment with the female block during assembly. - When correctly assembled the male and female fittings should be flush. - Use only the O-ring seals listed in the Ford Master Parts Catalog for the peanut fitting. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling Coupler HVAC: Service and Repair Spring Lock Coupling Spring Lock Coupling SPECIAL TOOL(S) DISCONNECT 1. Remove the A/C tube lock coupling clip, if equipped. 2. Fit the special tool to the spring lock coupling. 3. Push the tool into the cage opening to release the female fitting from the A/C tube lock coupling spring. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling > Page 7896 4. Pull the spring lock coupling fittings apart. 5. Remove the O-ring seals with a non-metallic tool. CAUTION: Do not use metal tools to remove the O-ring seals. They can cause axial scratches across the O-ring seal grooves, resulting in refrigerant leaks. 6. Remove the A/C tube lock coupling spring with a small hooked wire. CAUTION: Do not use a screwdriver or similar tool to remove the A/C tube lock coupling spring; this can cause axial scratches across the O-ring seal grooves resulting in refrigerant leaks. CLEANING 1. Fabricate a cleaning tool from a 1/8 inch diameter brazing rod. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling > Page 7897 2. Cut an abrasive pad from maroon colored 3M Scotch Brite(R) with the dimensions corresponding to the coupling size. 3. Assemble the pad to the tool. 4. Coat the abrasive pad with PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent. 5. Roll the pad on the tool and install it in a variable speed drill motor. 6. Polish for one minute at moderate speed (less than 1,500 rpm) or until the surface is clean and free of scratches or foreign material. CAUTION: Maintain low speed drill rotation when inserting or removing the cleaning tool to prevent axial scratches which may cause future leaks. 7. Clean the fitting with a lint-free cloth. 8. Inspect the surface for grooves or scratches. If grooves and scratches are still present, install a new component. 9. Clean the O-ring seal grooves with a 300 mm (12 inch) length of natural fiber string. - Loop the string around the grooves and pull the string back and forth. 10. Remove any foreign material from the grooves with a lint-free cloth. CONNECT Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling > Page 7898 1. Install the A/C tube lock coupling spring. 2. Lubricate the inside of the coupling with PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent. 3. Install the O-ring seals. - Lubricate the O-ring seals with PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent. CAUTION: Use only the new O-ring seals. The use of any O-ring seals other than those specified in the Ford Master Parts Catalog may result in intermittent leakage during vehicle operation. 4. Connect the spring lock coupling fittings with a twisting motion until the A/C tube lock coupling spring snaps over the flared end of the female fitting. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling > Page 7899 5. Install the A/C tube lock coupling clip. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling > Page 7900 Coupler HVAC: Service and Repair Air Conditioning Line (Peanut) Fitting DISCONNECT 1. Remove the nut from the peanut fitting. CAUTION: Support the female fitting with a wrench to prevent the tubes from twisting. 2. Pull the peanut fitting apart. 3. Remove the O-ring seal with a non-metallic tool. CAUTION: Do not use metal tools to remove the O-ring seal. They can cause axial scratches across the O-ring seal groove, resulting in refrigerant leaks. CONNECT 1. Clean all dirt or foreign material from the fittings. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling > Page 7901 2. Install the O-ring seal. - Lubricate the O-ring seal with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B. CAUTION: Use only the new O-ring seals. The use of any O-ring seals other than those specified in the Ford Master Parts Catalog may result in intermittent leakage during vehicle operation. 3. Lubricate the inside of the fittings with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B. 4. Assemble the male and female fittings together. NOTE: When correctly assembled, the male and female fittings should be flush. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Page 7902 Remover, Refrigerant Coupling Set Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Description and Operation Evaporator Case: Description and Operation The evaporator core housing is located in the engine compartment. The A/C evaporator housing assembly contains the following major components: - A/C evaporator core - blower motor - blower motor resistor Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Description and Operation > Page 7906 Evaporator Case: Service and Repair REMOVAL NOTE: - The evaporator core is not separately serviceable, it is serviced only with the evaporator core housing assembly. - Replacement of the suction accumulator is not required when repairing the refrigerant system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. - If an evaporator core leak is suspected, the evaporator core must be leak tested before it is removed from the vehicle. 1. Remove the suction accumulator. 2. Disconnect the blower motor and the blower motor resistor electrical connectors. 3. Detach the windshield wiper fluid hose. Using suitable hose pinching pliers, disconnect the heater hoses. 4. Detach the heater control valve vacuum hose. 5. Disconnect the heater control valve vacuum hose and the vacuum supply hose. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Description and Operation > Page 7907 6. Disconnect the condenser to evaporator tube spring lock coupling. 7. Disconnect the vacuum harness connector. Remove the nut. 8. Remove two nuts, one bolt, and the A/C evaporator housing. - Remove the nut located at the bottom of the A/C evaporator housing first. - To remove the A/C evaporator housing, rotate the A/C evaporator housing counterclockwise. Then tip the evaporator core end towards the front of the vehicle. INSTALLATION 1. To install, reverse the removal procedure. - Lubricate the refrigerant system with the correct amount of clean PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent. - Install new O-ring seals lubricated in amount of clean PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent. - Lubricate the coolant hoses with MERPOL(R) or plain water only, if needed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Description and Operation > Page 7908 Evaporator Case: Tools and Equipment Heater Hose Disconnect Tool Spring Lock Coupling Disconnect Tool (5/8 Inch) Disconnect Tool, Spring Lock Coupling Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Description and Operation > Page 7909 Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation Evaporator Core: Description and Operation NOTE: - The evaporator core is not separately serviceable, it is serviced only with the evaporator core housing assembly. - Installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. The A/C evaporator core is the plate/fin type with a unique refrigerant flow path. - A mixture of refrigerant and oil enters the bottom of the A/C evaporator core through the A/C evaporator core inlet tube and then moves out of the A/C evaporator core through the A/C evaporator core outlet tube. - This flow pattern accelerates the flow of refrigerant and oil through the A/C evaporator core. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Page 7913 Evaporator Core: Testing and Inspection ON-VEHICLE LEAK TEST 1. Discharge and recover the refrigerant. 2. Disconnect the suspect A/C evaporator core or A/C condenser core from the A/C system. NOTE: DO NOT leak test an A/C evaporator core with the suction accumulator/drier attached to the core tubes. 3. Clean the spring lock couplings. 4. Connect the appropriate test fittings from the R-12/R-134a Air Conditioning Test Fitting Set to the evaporator or condenser tube connections. 5. Connect the red and blue hoses from the R-134a Manifold Gauge Set to the test fittings on the A/C evaporator core or A/C condenser core. Connect the yellow hose to a known good vacuum pump. NOTE: The automatic shut-off valves on some gauge set hoses do not open when connected to the test fittings. If available, use hoses without shut-off valves. If hoses with shut-off valves are used, make sure the valve opens when attached to the test fittings or install an adapter which will activate the valve. The test is not valid if the shut-off valve does not open. 6. Open both gauge set valves and start the vacuum pump. Allow the vacuum pump to operate for a minimum of 45 minutes after the gauge set low pressure gauge indicates 101 kPa (30 in-Hg). The 45 minute evacuation is necessary to remove any refrigerant from oil left in the A/C evaporator core or A/C condenser core. If the refrigerant is not completely removed from the oil, outgassing will degrade the vacuum and appear as a refrigerant leak. 7. If the low pressure gauge reading will not drop to 101 kPa (30 in-Hg) when the valves on the gauge and manifold set are open and the vacuum pump is operating, close the gauge set valves and observe the low pressure gauge. If the pressure rises rapidly to zero, a large leak is indicated. Recheck the test fitting connections and gauge set connections before installing a new A/C evaporator core or A/C condenser core. 8. After evacuating for 45 minutes, close the gauge set valves and stop the vacuum pump. Observe the low pressure gauge; it should remain at the 101 kPa (30 in-Hg) mark. If the low pressure gauge reading rises 34 or more kPa (10 or more in-Hg) of vacuum from the 101 kPa (30 in-Hg) position in 10 minutes, a leak is indicated. - If a very small leak is suspected, wait 30 minutes and observe the vacuum gauge. - If a small amount of vacuum is lost, operate the vacuum pump with gauge valves open for an additional 30 minutes to remove any remaining refrigerant from the oil in the A/C evaporator core or A/C condenser core. Then recheck for loss of vacuum. - If a very small leak is suspected, allow the system to set overnight with vacuum applied and check for vacuum loss. 9. If the A/C evaporator core or A/C condenser core does leak, as verified by the above procedure, install a new A/C evaporator core or A/C condenser core. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Page 7914 Evaporator Core: Service and Repair REMOVAL NOTE: - The evaporator core is not separately serviceable, it is serviced only with the evaporator core housing assembly. - Installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. - If an evaporator core leak is suspected, the evaporator core must be leak tested before it is removed from the vehicle. 1. Remove the evaporator core housing. 2. Transfer components from the old evaporator core housing to the new evaporator core housing. INSTALLATION 1. Install the evaporator core housing. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Page 7915 Evaporator Core: Tools and Equipment Spring Lock Coupling Disconnect Tool Set Spring Lock Coupling Disconnect Tool Set Disconnect Tool, Spring Lock Coupling Heater Hose Disconnect Tool Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Page 7916 Special Tool(s) Set, A/C Fittings Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Description and Operation Evaporator Temperature Sensor/Clutch Cycling Switch: Description and Operation Air Conditioning Evaporator Temperature Sensor A/C Evaporator Temperature (ACET) Sensor Voltage And Resistance Chart, Part 1 A/C Evaporator Temperature (ACET) Sensor Voltage And Resistance Chart, Part 2 The Air Conditioning Evaporative Temperature (ACET) sensor senses evaporator air discharge temperature. The ACET sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The PCM sources a low current 5 volts on the ACET circuit. With SIG RTN also connected to the ACET sensor, the varying resistance affects the voltage drop across the sensor terminals. As A/C evaporator air temperature changes, the varying resistance of the ACET sensor changes the voltage the PCM detects. The ACET sensor is used to more accurately control A/C clutch cycling, improving defrost/demist performance, reduce A/C clutch cycling, etc. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Diagrams > Page 7923 Expansion Block/Orifice Tube: Description and Operation A/C Evaporator Core Orifice NOTE: A new A/C evaporator core orifice should be installed whenever a new A/C compressor is installed. The A/C evaporator core orifice has the following characteristics: - It is color-coded red. - It is located in the A/C evaporator core inlet tube. - It has filter screens located on the inlet and outlet ends of the tube body. - The inlet filter screen acts as a Strainer for the liquid refrigerant flowing through the A/C evaporator core orifice. - O-rings on the A/C evaporator core orifice prevent the high-pressure liquid refrigerant from bypassing the A/C evaporator core orifice. - Adjustment or service cannot be made to the A/C evaporator core orifice assembly. A new evaporator core orifice assembly must be installed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Diagrams > Page 7924 Expansion Block/Orifice Tube: Service and Repair SPECIAL TOOL(S) REMOVAL All vehicles 1. Prepare the vehicle for evaporator core orifice removal. 1 Disconnect the battery ground cable. 2 Recover the refrigerant. 3 Remove the air cleaner assembly. 2. Detach the speed control servo. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Position the speed control servo aside. 3. Position the coolant expansion tank/windshield washer reservoir aside. 1 Remove the screws and the nuts. 2 Position the coolant expansion tank/windshield washer reservoir aside. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Diagrams > Page 7925 4. Disconnect the condenser to evaporator tube spring lock coupling. 5. Inspect the evaporator core orifice for damage. Vehicles with a serviceable evaporator core orifice 6. Engage the special tool with the evaporator core orifice. 7. Holding the special tool T-handle stationary, rotate the special tool body to remove the evaporator core orifice. Vehicles with a damaged or broken evaporator core orifice Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Diagrams > Page 7926 8. Screw the end of the special tool into the broken evaporator core orifice. 9. Holding the special tool T-handle stationary, rotate the special tool body to remove the broken evaporator core orifice. INSTALLATION 1. Install new O-ring seals on the evaporator core orifice. - Lubricate the new O-ring seals with PAG oil or equivalent. 2. Position the evaporator core orifice in the special tool. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Diagrams > Page 7927 3. Using the special tool, install the evaporator core orifice. 4. Install the coolant expansion tank/windshield washer reservoir. 1 Install the coolant expansion tank/windshield washer reservoir aside. 2 Install the screws and the nuts. 5. Install the speed control servo. 1 Install the speed control servo. 2 Install the bolt. 3 Connect the electrical connector. 6. Restore the vehicle to operating condition. 1 Install the air cleaner assembly. 2 Connect the battery ground cable. 3 Evacuate, leak test, and charge the A/C system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Diagrams > Page 7928 Expansion Block/Orifice Tube: Tools and Equipment Spring Lock Coupling Disconnect Tool Set Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Locations Expansion Valve: Locations For further information regarding this component please refer to: Heating and Air Conditioning; Expansion Block/Orifice Tube. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Control Valve > Component Information > Service and Repair Heater Control Valve: Service and Repair REMOVAL 1. Prepare the vehicle for heater water control valve assembly removal. 1 Drain the engine coolant. 2 Remove the air cleaner assembly. 2. Disconnect the vacuum hose and heater hose. 3. Remove the retaining pins. Position the inner fender well access mat out of the way. 4. Disconnect the heater hose. Remove the bolt and the heater water control valve assembly. INSTALLATION 1. To install, reverse the removal procedure. - Lubricate the coolant hoses with MERPOL(R) meeting Ford specification ESE-M99B144-B or plain water only, if needed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 7943 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 7944 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 7950 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 7951 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 7952 Heater Core: Service Precautions WARNING: - CARBON MONOXIDE IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS NECESSARY TO OPERATE THE ENGINE WITH THE VEHICLE IN A CLOSED AREA SUCH AS A GARAGE, ALWAYS USE AN EXHAUST COLLECTOR TO VENT THE EXHAUST GASES OUTSIDE THE CLOSED AREA. THE HEATER CORE INLET HOSE WILL BECOME TOO HOT TO HANDLE IF THE SYSTEM IS WORKING CORRECTLY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 7953 Heater Core: Description and Operation The heater core consists of fins and tubes arranged to extract heat from the engine coolant and transfer it to air passing through the heater core. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 7954 Heater Core: Testing and Inspection WARNING: CARBON MONOXIDE IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS NECESSARY TO OPERATE THE ENGINE WITH THE VEHICLE IN A CLOSED AREA SUCH AS A GARAGE, ALWAYS USE AN EXHAUST COLLECTOR TO VENT THE EXHAUST GASES OUTSIDE THE CLOSED AREA. 1. Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A coolant leak in the heater water hose could follow the heater core tube to the heater core and appear as a leak in the heater core. NOTE: Testing of returned heater cores reveals that a large percentage of heater cores are good and did not require installation of a new heater core. If a heater core leak is suspected, the heater core must be tested by following the plugged heater core component test before the heater core pressure test. Carry out a system inspection by checking the heater system thoroughly. 2. Check the integrity of the heater water hose clamps. NOTE: Spring-type clamps are installed as original equipment. Installation and overtightening of non-specification clamps can cause leakage at the heater water hose connection and damage the heater core. Heater Core - Plugged WARNING: THE HEATER CORE INLET HOSE WILL BECOME TOO HOT TO HANDLE IF THE SYSTEM IS WORKING CORRECTLY. 1. Check to see that the engine coolant is at the correct level. 2. Start the engine and turn on the heater. 3. When the engine coolant reaches operating temperature, feel the heater core outlet hose to see if it is hot. If it is not hot: the heater control valve is not working correctly. - the heater core may have an air pocket. - the heater core may be plugged. - the thermostat is not working correctly. Heater Core - Pressure Test Use Pressure Tester to carry out the pressure test. 1. Drain the coolant from the cooling system. NOTE: Due to space limitations, a bench test may be necessary for pressure testing. 2. Disconnect the heater water hoses from the heater core. 3. Install a short piece of heater water hose, approximately 101 mm (4 inches) long on each heater core tube. 4. Fill the heater core and heater water hoses with water and install Plug BT-7422-B and adapter BT-7422-A from the radiator/heater core pressure tester in the heater water hose ends. Secure the heater water hoses, plug and adapter with hose clamps. 5. Attach the pump and gauge assembly from the Pressure Tester to the adapter. 6. Close the bleed valve at the base of the gauge. Pump 241 kPa (35 psi) of air pressure into the heater core. 7. Observe the pressure gauge for a minimum of three minutes. 8. If the pressure drops, check the heater water hose connections to the core tubes for leaks. If the heater water hoses do not leak, remove the heater core from the vehicle and carry out the bench test. Heater Core - Bench Test 1. Remove the heater core from the vehicle. 2. Drain all of the coolant from the heater core. 3. Connect the 101 mm (4 inch) test heater water hoses with plug and adapter to the core tubes. Then connect the radiator/heater core pressure tester to the adapter. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 7955 4. Apply 241 kPa (35 psi) of air pressure to the heater core. Submerge the heater core in water. 5. If a leak is observed, install a new heater core. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 7956 Heater Core: Service and Repair REMOVAL 1. Prepare the vehicle for heater core removal. 1 Remove the A/C evaporator housing. 2 Remove the instrument panel. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Removal and Installation, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 3 Remove the Powertrain Control Module (PCM). NOTE: If a heater core leak is suspected, the heater core must be leak tested before it is removed from the vehicle. 2. Remove the PCM heat sink. 1 Remove the ground strap screw. 2 Remove the heat sink. 3. Remove the four nuts from the engine side of the dash panel. Position the plenum chamber on the vehicle floor. 4. Remove the heater core cover. 1 Remove the screws. 2 Remove the heater core cover. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 7957 5. Remove the heater core. - During installation, be sure to install a new oval foam seal around the heater core inlet and outlet tubes. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 7966 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 7967 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 7973 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 7974 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Description and Operation High Pressure Safety Valve HVAC: Description and Operation An A/C compressor pressure relief valve is incorporated in the compressor A/C manifold and tube to: - relieve unusually high refrigerant system discharge pressure buildups. For specifications regarding operating pressure(s), refer to Specifications. - prevent damage to the A/C compressor and other system components. - avoid total refrigerant loss by closing after the excessive pressure has been relieved. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 04-25-11 > Dec > 04 > A/C - Moaning From Engine Compartment Hose/Line HVAC: Customer Interest A/C - Moaning From Engine Compartment TSB 04-25-11 12/27/04 MOAN/VIBRATION DURING A/C OPERATION FORD: 2001-2005 Explorer Sport Trac ISSUE Some 2001-2005 Explorer Sport Trac vehicles may exhibit a moan/vibration coming from the engine compartment while the A/C is on and the engine is at low RPM. The noise will only occur when the A/C compressor is running. ACTION Replace the manifold and tube assembly on the A/C compressor. Refer to Workshop Manual Section 412-03. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042511A Replace The Manifold And 1.7 Hrs. Tube Assembly On The A/C Compressor (Includes Time To Recover, Evacuate And Charge The Air Conditioning System) DEALER CODING CONDITION BASIC PART NO. CODE 19D734 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 04-25-11 > Dec > 04 > A/C - Moaning From Engine Compartment Hose/Line HVAC: All Technical Service Bulletins A/C - Moaning From Engine Compartment TSB 04-25-11 12/27/04 MOAN/VIBRATION DURING A/C OPERATION FORD: 2001-2005 Explorer Sport Trac ISSUE Some 2001-2005 Explorer Sport Trac vehicles may exhibit a moan/vibration coming from the engine compartment while the A/C is on and the engine is at low RPM. The noise will only occur when the A/C compressor is running. ACTION Replace the manifold and tube assembly on the A/C compressor. Refer to Workshop Manual Section 412-03. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042511A Replace The Manifold And 1.7 Hrs. Tube Assembly On The A/C Compressor (Includes Time To Recover, Evacuate And Charge The Air Conditioning System) DEALER CODING CONDITION BASIC PART NO. CODE 19D734 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Page 7991 Hose/Line HVAC: Description and Operation NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. The condenser to evaporator tube contains high pressure liquid refrigerant upstream of the A/C evaporator core orifice. The A/C manifold and tube is attached to the A/C compressor, is sealed with O-ring seals, and has the following features: - The upstream side contains low pressure refrigerant gas. - The downstream side contains high pressure refrigerant gas and a fitting used to mount a serviceable high-pressure A/C charge port valve. - The downstream side also contains a fitting used to mount the A/C pressure cutoff switch. A long-travel Schrader-type valve stem core is installed in the fitting so that the A/C pressure cutoff switch can be removed without discharging the A/C system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Page 7992 Hose/Line HVAC: Service and Repair REMOVAL 1. Prepare the vehicle for condenser to evaporator tube removal. 1 Disconnect the battery ground cable. 2 Recover the refrigerant. 3 Remove the air cleaner assembly. 2. Disconnect the condenser to evaporator tube from the A/C condenser core. Remove and discard the O-ring seal. - During installation, install a new O-ring seal lubricated with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B. 3. Disconnect and remove the condenser to evaporator tube. INSTALLATION 1. To install, reverse the removal procedure. 2. Evacuate, leak test, and charge the A/C system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair Housing Assembly HVAC: Service and Repair REMOVAL 1. Prepare the vehicle for plenum chamber removal. 1 Remove the instrument panel. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Removal and Installation, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 2 Remove the A/C evaporator housing. 3 Remove the Powertrain Control Module (PCM). 2. Remove the PCM heat sink. 1 Remove the ground strap screw. 2 Remove the PCM heat sink. 3. Remove the four nuts and the plenum chamber. NOTE: To ease the removal of the plenum chamber, first remove the nut located at the center of the dash panel behind the engine cylinder block. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Description and Operation Receiver Dryer: Description and Operation For further information regarding this component please refer to: Accumulator HVAC. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Capacity 0.85 kg (30 oz) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 8003 Refrigerant: Fluid Type Specifications Refrigerant Fluid Type Refrigerant Fluid Type R-134a Refrigerant YN-19 WSH-M17B19-A Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service Precautions > Environmental Impact Information Refrigerant: Environmental Impact Information The Ozone Layer A thin layer of ozone molecules, located 10 to 30 miles above the earth, form a protective cover by absorbing a portion of the ultraviolet (UV) radiation emitted from the Sun. Ozone Depletion Scientific research performed over the past 15 years links the release of chlorofluorocarbons (CFC)s, also know by the trade name Freon) into the atmosphere to ozone depletion. When CFCs are released into the atmosphere, they eventually reach the ozone layer located in the stratosphere where they react with and destroy ozone molecules. Harmful Effects Ozone depletion and the corresponding increase in UV radiation has been shown to lead to higher incidents of cancer as well as global warming. When viewed from a global perspective, ozone depletion holds an enormous potential for damage. Upper Level Vs. Ground Level Ozone Confusion often arises when we hear about the necessity of the ozone layer and ground level ozone. The ozone layer existing high above the earth is beneficial but the same compound, when located at ground level, is harmful to humans, animals, crops and vegetation. Ground level ozone is a component of smog and forms when hydrocarbons (HC) react with nitrogen oxides (NOx) in the presence of sunlight and heat. Montreal Protocol In response to the growing body of evidence demonstrating the detrimental effects of (CFC)s, 24 countries and the European community met in Montreal, Canada, in 1987 to establish standards for the control of (CFC)s. Since that time, a total of 132 countries have become signatories to this agreement leading to an end of production of R12 in December, 1995, in all developed countries. As established by the Montreal Protocol, R12 production in developed countries has ceased. Clean Air Act The United States Congress, acting in response to the Montreal Protocol, banned production of (CFC)s by the year 2000. Congress also amended the Clean Air Act in an effort to control both the production and use of (CFC)s for refrigerant applications including mobile vehicle air conditioning systems. Additional Information Sources For more complete and detailed explanations of the above policies, please refer to: http://www.epa.gov/ozone/ Technician Certification Organizations providing technician refrigerant recovery and recycling certification include: National Institute for Automotive Service Excellence (ASE) 13505 Dulles Technology Drive, Suite 2 Herndon, VA 22071-3421 Phone: (703) 713-3800 Fax: (703) 713-0727 http://www.asecert.org/ International Mobile Air Conditioning Association (IMACA) P.O. Box 9000 Fort Worth, TX 76147-2000 Phone: (817) 732-4600 Fax: (817) 732-9610 http://www.imaca.org/ Mobile Air Conditioning Society (MACS) Worldwide P.O. Box 100 East Greenville, PA 18041 Phone: 215-679-2220 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service Precautions > Environmental Impact Information > Page 8006 Fax: 215-541-4635 http://www.macsw.org/ Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service Precautions > Environmental Impact Information > Page 8007 Refrigerant: Vehicle Damage Warnings CAUTION: - Good ventilation is necessary in the area where electronic A/C leak testing is to be carried out. If the surrounding air is contaminated with refrigerant gas, the leak detector will indicate this gas all the time. Odors from other chemicals such as anti-freeze, diesel fuel, disc brake cleaner, or other cleaning solvents can cause the same problem. A fan, even in a well-ventilated area, is very helpful in removing small traces of contamination from the air that might affect the leak detector. - If contaminated refrigerant is detected, DO NOT recover the refrigerant into R-134a or R-12 recovery/recycling equipment. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Testing and Inspection > Electronic Leak Detection Refrigerant: Testing and Inspection Electronic Leak Detection Refrigerent Leak Detector SPECIAL TOOL(S) CAUTION: Good ventilation is necessary in the area where electronic A/C leak testing is to be carried out. If the surrounding air is contaminated with refrigerant gas, the leak detector will indicate this gas all the time. Odors from other chemicals such as anti-freeze, diesel fuel, disc brake cleaner, or other cleaning solvents can cause the same problem. A fan, even in a well-ventilated area, is very helpful in removing small traces of contamination from the air that might affect the leak detector. 1. Leak test the refrigerant system using the Refrigerant Leak Detector. Follow the instructions included with the leak detector for handling and operation techniques. NOTE: The system pressure should be between 413-551 kPa (60-80 psi) at 24°C (75°F) with the engine off. 2. If a leak is found, discharge and recover the refrigerant. - Repair the system. - Test the system for normal operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Testing and Inspection > Electronic Leak Detection > Page 8010 Refrigerant: Testing and Inspection Tracer Dye Leak Detection 120 Watt 110 Volt UV Lamp 20 Degree Celsius SPECIAL TOOL(S) NOTE: Ford Motor Company vehicles are produced with a permanent leak tracer dye incorporated into the A/C system. The location of leaks can be pinpointed by the bright yellow-green glow of the tracer dye. Since more than one leak can exist, always inspect each component. 1. Check for leaks using a 120 Watt UV spot lamp. - Scan all components, fittings and lines of the A/C system. 2. After the leak is repaired, remove any traces of tracer dye with a general purpose oil solvent. 3. Verify the repair by operating the system for a short time and inspect with the UV spot lamp. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Refrigerant Discharging and Recovery Procedure Refrigerant: Service and Repair Refrigerant Discharging and Recovery Procedure Special Tool(s) SPECIAL TOOL(S) Refrigerant System Recovery NOTE: Ford Motor Company recommends use of an A/C service center to carry out recovery, evacuation, and charging of the refrigerant system. If an A/C service center is not available, refrigerant system recovery, evacuation, and charging may be accomplished using a separate recovery station, vacuum pump, charging cylinder, and manifold gauge set. 1. Prior to recovering the refrigerant system, you must verify the purity of the refrigerant. 2. Connect an R-134a A/C service center to the low- and high-pressure service gauge port valves. NOTE: Some R-134a service centers require the use of an A/C manifold gauge set. 3. Recover the refrigerant from the system following the operating instructions provided by the equipment manufacturer. 4. Once the service center has recovered the vehicle A/C system refrigerant, close the service center inlet valve (if equipped). Then switch off the power supply. 5. Allow the vehicle A/C system to remain closed for about two minutes. Observe the system vacuum level as shown on the gauge. If the vacuum does not decrease, disconnect the refrigerant center hose(s). 6. If the system vacuum does decrease, repeat Steps 2 through 5 until the vacuum level remains stable for two minutes. 7. Carry out the required repairs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Refrigerant Discharging and Recovery Procedure > Page 8013 Refrigerant: Service and Repair Identifying Refrigerants Delux A/C Refrigerant Analyzer SPECIAL TOOL(S) 1. Follow the instructions included with the Deluxe Refrigerant Diagnostic Tool to obtain the sample for testing. NOTE: An A/C refrigerant analyzer must be used to identify gas samples taken directly from the refrigeration system or storage containers prior to recovering or charging the refrigerant system. 2. The diagnostic tool will display one of the following: - If the purity level of R-134a or R-12 is 98% or greater by weight, the green "PASS" Light Emitting Diode (LED) will light. The weight concentrations of R-134a, R-12, R-22, hydrocarbons, and air will be displayed on the digital display. - If refrigerants R-134a or R-12 do not meet the 98% purity levels, the red "FAIL" LED will light and a horn will sound alerting the user of potential hazards. The weight concentrations of R-134a, R-12, R-22, and hydrocarbons will be displayed on the digital display. - If hydrocarbon concentrations are 2% or greater by weight, the red "FAIL" LED will light, "Hydrocarbon High" will be displayed on the digital display, and a horn will sound alerting the user of potential hazards. The weight concentrations of R-134a, R-12, R-22, and hydrocarbons will also be displayed on the digital display. 3. The percentage of air contained in the sample will be displayed if the R-134a or R-12 content is 98% or greater. The diagnostic tool eliminates the effect of air when determining the refrigerant sample content because air is not considered a contaminant, although air can affect A/C system performance. When the diagnostic tool has determined that a refrigerant source is pure (R-134a or R-12 is 98% or greater by weight) and air concentration levels are 2% or greater by weight, the diagnostic tool will prompt the user if an air purge is desired. 4. If contaminated refrigerant is detected, repeat the refrigerant identification test to verify that the refrigerant is indeed contaminated. 5. Recover any contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant. CAUTION: If contaminated refrigerant is detected, DO NOT recover the refrigerant into R-134a or R-12 recovery/recycling equipment. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Refrigerant Discharging and Recovery Procedure > Page 8014 Refrigerant: Service and Repair Handling of Contaminated Refrigerants 1. Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant. - This equipment must only be used to recover contaminated refrigerant to prevent the spread to other vehicles. - If this equipment is not available, contact an A/C repair facility in your area with the correct equipment to carry out this repair. CAUTION: If contaminated refrigerant is detected, DO NOT recover the refrigerant into your recovery/recycling equipment. 2. Determine and correct the cause of the customer's initial concern. 3. The suction accumulator/drier cannot be cleaned and a new suction accumulator/drier must be installed. Remove the suction accumulator/drier. NOTE: Residual refrigerant oil in the suction accumulator/drier must be drained and measured for correct oil system matching. 4. Clean the A/C evaporator core and the A/C condenser core by flushing. 5. Install the new suction accumulator/drier. 6. Correctly oil match the system. 7. Evacuate and charge the system. 8. Dispose of contaminated refrigerant according to all federal, state and local regulations. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Refrigerant Discharging and Recovery Procedure > Page 8015 Refrigerant: Service and Repair Evacuation and Charging Special Tool(s) SPECIAL TOOL(S) Refrigerant System Evacuation NOTE: Ford Motor Company recommends use of an A/C service center to carry out recovery, evacuation, and charging of the refrigerant system. If an A/C service center is not available, refrigerant system recovery, evacuation, and charging may be accomplished using a separate recovery station, vacuum pump, charging cylinder, and manifold gauge set. 1. Connect an R-134a service center to the low- and high-pressure service gauge port valves. 2. Evacuate the system until the low-pressure gauge reads at least 99.4 kPa (29.5 in-Hg) of vacuum and as close to 101.1 kPa (30 in-Hg) as possible. Continue to operate the vacuum pump for a minimum of 45 minutes. 3. Turn off the vacuum pump. Observe the low-pressure gauge for five minutes to make sure that the system vacuum is held. If vacuum is not held for five minutes, leak test the system, service the leak, and evacuate the system again. Refrigerant System Charging NOTE: Ford Motor Company recommends use of an A/C service center to carry out recovery, evacuation, and charging of the refrigerant system. If an A/C service center is not available, refrigerant system recovery, evacuation, and charging may be accomplished using a separate recovery station, vacuum pump, charging cylinder, and manifold gauge set. 1. Correctly oil match the system to verify that the correct amount of refrigerant oil is present in the system. 2. Charge the system with the specified amounts of refrigerant oil and refrigerant. 3. When no more refrigerant is being drawn into the system, start the engine and select MAX A/C operation. Adjust the blower motor speed to the maximum and allow the remaining refrigerant to be drawn into the system. Continue to add refrigerant into the system until the specified weight of R-134a has been added. Close the charging cylinder valve and allow the system to pull any remaining refrigerant from the hose. When the low-pressure drops to approximately 207 kPa (30 psi), close the charging hose valve. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Page 8016 Refrigerant: Tools and Equipment Refrigerent Leak Detector 120 Watt 110 Volt UV Lamp 20 Degree Celsius Special Tool(s) Delux A/C Refrigerant Analyzer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Capacity 266 ml (9 oz) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 8021 Refrigerant Oil: Fluid Type Specifications Refrigerant Oil Type Refrigerant Oil Type PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) WSH-M1C231-B Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 8022 Refrigerant Oil: Service Precautions CAUTION: During normal A/C operation, oil is circulated through the system with the refrigerant, and a small amount is retained in each component. If certain components of the system are removed for new installation, some of the refrigerant oil will go with the component. To maintain the original total oil charge, it is necessary to compensate for the oil lost by adding oil to the system with the new part. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 8023 Refrigerant Oil: Service and Repair REFRIGERANT OIL ADDITION CAUTION: During normal A/C operation, oil is circulated through the system with the refrigerant, and a small amount is retained in each component. If certain components of the system are removed for new installation, some of the refrigerant oil will go with the component. To maintain the original total oil charge, it is necessary to compensate for the oil lost by adding oil to the system with the new part. 1. Rotate the A/C compressor shaft six to eight revolutions while collecting oil in a clean measuring device. - If the amount of oil drained from the old A/C compressor is between 85-142 ml (3-5 ounces), pour the same amount plus 30 ml (1 ounce) of clean PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) WSH M1C231-B or equivalent into the new A/C compressor. - If the amount of oil that was removed from the old A/C compressor is greater than 142 ml (5 ounces), pour the same amount drained of clean PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent into the new A/C compressor. - If the amount of oil that was removed from the old A/C compressor is less than 85 ml (3 ounces), pour 85 ml (3 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent into the new A/C compressor. NOTE: Service A/C compressors are shipped without compressor oil. 2. For the suction accumulator/drier, drill one 13 mm (0.52 in) hole in the suction accumulator/drier cylinder and drain the oil into a calibrated container. Add a quantity of new oil to match that drained from the old suction accumulator/drier plus 60 ml (2 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent. 3. For the A/C evaporator core, add 89 ml (3 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent to the suction accumulator/drier inlet tube. 4. For the A/C condenser core, add 30 ml (1 ounce) of clean PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent to the A/C condenser core or the suction accumulator/drier inlet tube. 5. Add 60 ml (2 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent to the suction accumulator/drier inlet tube when carrying out each of the following repairs: installation of a new A/C evaporator core orifice - installation of a new A/C compressor pressure relief valve - installation of a new refrigerant line - repair of an O-ring seal leak - repair of a charge port leak 6. Installation of new components that do not require discharge of refrigerant and resulting oil loss, such as the A/C cycling switch and the A/C pressure transducer, do not require additional oil. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Diagrams Connector View C1078 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations Blower Motor Relay: Locations Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 8032 Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 8033 Connector View C1011 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 8034 Blower Motor Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 8035 Relay - Micro ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 8039 Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 8040 Connector View C1008 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 8041 Compressor Clutch Relay: Description and Operation Wide Open Throttle A/C Cut-Off The wide open throttle A/C cutoff relay (may be referred to as the A/C clutch relay) is normally open. There is no direct electrical connection between the A/C switch or EATC Module and the A/C clutch. The PCM will receive a signal indicating that A/C is requested (for some applications, this message is sent through the BUS + and BUS - circuits). When A/C is requested, the PCM will check other A/C related inputs that are available (such as ACP (SW), A/C Cycling Switch (ACCS)). If these inputs indicate A/C operation is OK, and the engine conditions are OK (such as coolant temperature, engine rpm, throttle position), the PCM will ground the Wide Open Throttle A/C (WAC) output, closing the relay contacts and sending voltage to the A/C clutch. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 8042 Compressor Clutch Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 8043 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations Condenser Fan Motor Relay: Locations Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 8047 Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 8048 Connector View C1056 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 8049 Condenser Fan Motor Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 8050 Relay - Micro ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations View 151-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 8055 Connector View C132 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Description and Operation Blower Motor Switch: Description and Operation The blower motor switch controls blower motor speed by adding or by passing resistors in the heater blower motor switch resistor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor/Clutch Cycling Switch <--> [Evaporator Temperature Sensor / Switch] > Component Information > Description and Operation Evaporator Temperature Sensor/Clutch Cycling Switch: Description and Operation Air Conditioning Evaporator Temperature Sensor A/C Evaporator Temperature (ACET) Sensor Voltage And Resistance Chart, Part 1 A/C Evaporator Temperature (ACET) Sensor Voltage And Resistance Chart, Part 2 The Air Conditioning Evaporative Temperature (ACET) sensor senses evaporator air discharge temperature. The ACET sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The PCM sources a low current 5 volts on the ACET circuit. With SIG RTN also connected to the ACET sensor, the varying resistance affects the voltage drop across the sensor terminals. As A/C evaporator air temperature changes, the varying resistance of the ACET sensor changes the voltage the PCM detects. The ACET sensor is used to more accurately control A/C clutch cycling, improving defrost/demist performance, reduce A/C clutch cycling, etc. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Diagrams Connector View C1078 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations Service Port HVAC: Locations Refrigerant System Components Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations > Page 8069 Service Port HVAC: Description and Operation Service Gauge Port Valve The high-pressure service gauge port valve is located on the front A/C manifold and tube. The low pressure service gauge port valve is located on the suction accumulator. The fitting is an integral part of the refrigeration line or component. - Special couplings are required for both the high-side and low-side service gauge ports. - A new Schrader-type valve core can be installed if the seal leaks. - Always install the A/C charging valve cap on the service gauge port valves after repairing the refrigerant system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service Precautions > Customer Safety Information Vacuum Harness HVAC: Customer Safety Information WARNING: BEFORE USING, OR HANDLING COMMERCIALLY AVAILABLE PAINT THINNER CONTAINING METHYL ETHYL KETONE (MEK), READ AND FOLLOW THE WARNING INFORMATION ON THE PRODUCT LABEL. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service Precautions > Customer Safety Information > Page 8074 Vacuum Harness HVAC: Technician Safety Information WARNING: READ THE WARNING INFORMATION ON THE PRODUCT LABEL TO PREVENT POSSIBLE PERSONAL INJURY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service Precautions > Page 8075 Vacuum Harness HVAC: Service and Repair Vacuum Pump Kit SPECIAL TOOL(S) 1. Measure the length of the damaged area of the mini-tube vacuum hose. 2. Cut a piece of standard 1/8 inch inner diameter vacuum hose approximately 25 mm (1 inch longer than the damaged area of the mini-tube vacuum hose). 3. Cut off the mini-tube vacuum hose on each side of the damaged area. 4. Dip the mini-tube hose ends in commercially available paint thinner containing Methyl Ethyl Ketone (MEK). This solvent will seal the mini-tube in the vacuum hose. WARNING: READ THE WARNING INFORMATION ON THE PRODUCT LABEL TO PREVENT POSSIBLE PERSONAL INJURY. 5. Insert the ends of the mini-tube vacuum hose approximately 9 mm (3/8 inch) into the ends of the standard 1/8 inch repair vacuum hose section. 6. Shake the repair joint after assembly to make sure the solvent is dispersed and the vacuum line is not plugged. 7. Test the system for a vacuum leak in the repair area. - Use the Vacuum Tester or equivalent. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service Precautions > Page 8076 Vacuum Tester Kit Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Service and Repair Vacuum Reservoir HVAC: Service and Repair REMOVAL 1. Prepare the vehicle for vacuum reservoir removal. 1 Disconnect the battery ground cable. 2 Remove the air cleaner assembly. 2. Remove the screws. Position the air cleaner housing mounting bracket out of the way. 3. Raise and support the vehicle. 4. Remove the screws. 5. Lower the vehicle. 6. Label and disconnect the vacuum hoses. Remove the vacuum reservoir. NOTE: The vacuum hoses to the vacuum reservoir are not interchangeable. Note the location of each vacuum hose to make sure of correct installation. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Inspection and Repair After A Supplemental Restraint System (SRS) Deployment Repairs and Inspections Required After a Collision: Service and Repair Inspection and Repair After A Supplemental Restraint System (SRS) Deployment WARNING: IF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS BEING SERVICED, THE SYSTEM MUST BE DEACTIVATED AND RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED. THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. NOTE: ^ Diagnostics or repairs are not to be performed on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ After diagnosing or repairing a SRS the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ After diagnosing or repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. When any deployable device (driver air bag, passenger air bag, seat side air bag, safety belt pretensioner, etc.) or combination of devices are deployed and the RCM has the DTC B1231 (Crash Data Memory Full) in memory, the repair of the vehicle's Supplemental Restraint System (SRS) is to include the removal and installation of all deployed devices and all impact sensors and the removal and installation of the RCM. 2. When any damage to the impact sensor mounting points or mounting hardware has occurred, repair or install new mounting points and mounting hardware as needed. 3. Inspect the entire vehicle for damage, including the following components: ^ steering column and clockspring. ^ instrument panel knee bolsters and mounting points. ^ instrument panel braces and brackets. ^ instrument panel and mounting points. ^ seats and seat mounting points. ^ safety belts, safety belt buckles, and safety belt retractors. ^ supplemental restraint system (SRS) wiring, wiring harnesses, and connectors. 4. After carrying out the review and inspection of the entire vehicle for damage, repair or install new components as needed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Inspection and Repair After A Supplemental Restraint System (SRS) Deployment > Page 8085 Repairs and Inspections Required After a Collision: Service and Repair Safety Belt Procedure After A Collision 1. Before installing the new safety belt assembly, the safety belt attaching areas must be inspected for damage and distortion. If the attaching points are damaged and distorted, the sheet metal must be reworked back to its original shape and structural integrity. Install the new safety belt(s) using the appropriate instructions. Perform the Functional Test. See: Safety Belt Systems/Testing and Inspection/Component Tests and General Diagnostics/Functional Test WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS, IF SO EQUIPPED, CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE CORRECTLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. NOTE: Safety belt assemblies should be periodically inspected to make sure they have not become damaged and that they remain in correct operating condition, particularly if they have been subjected to severe stress. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Customer Safety Information Air Bag(s) Arming and Disarming: Customer Safety Information WARNING: ^ IF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS BEING SERVICED, THE SYSTEM MUST BE DEACTIVATED AND RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED. ^ THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, TURN THE IGNITION OFF AND DISCONNECT THE BATTERY GROUND CABLE, WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Customer Safety Information > Page 8091 Air Bag(s) Arming and Disarming: Technician Safety Information WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, CAUTIONS, AND NOTES AT THE BEGINNING OF THE DEACTIVATION PROCEDURE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Customer Safety Information > Page 8092 Air Bag(s) Arming and Disarming: Vehicle Damage Warnings CAUTION: ^ Do not handle the passenger air bag module by grabbing the edges of the deployment door. ^ Do not deactivate the side air bag module circuit be removing the side air bag bridge resistor from the side air bag to floor connector. ^ If the side air bag bridge resistor is removed, an open circuit fault will be generated by the Restraints Control Module (RCM). ^ If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Deactivation Procedure Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will This will reduce the risk of injury in the event of an accidental deployment. WARNING: To reduce the risk of personal injury, do not use any memory saver devices. NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood connected. WARNING: To reduce the risk of personal injury, do not use any memory saver devices. NOTE: The air bag warning lamp illuminates when the RGM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8095 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, See: Starting and Charging/Battery 7. Remove the two steering wheel back cover plugs. 8. Remove the driver air bag module retaining bolts. 9. Remove the driver air bag module. 1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8096 10. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector at the top of the steering column. 11. Open the glove compartment door past its stops to access the mounting screws. 12. Remove the two screws. 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Reaching one hand into the glove compartment opening push out on the passenger air bag module and separate it from the instrument panel. Note the wire harness routing for installation. 14. Disconnect the electrical connector and remove the passenger air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8097 15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. Vehicles without seat side air bags 16. CAUTION: Do not deactivate the side air bag module circuit be removing the side air bag bridge resistor from the side air bag to floor connector. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM). If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. Vehicles with seat side air bags and power driver seat 17. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. For additional information, See: Starting and Charging/Battery Vehicles with seat side air bags 18. Move and tilt the front seats to their highest and most forward position. Vehicles with seat side air bags and power driver seat 19. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, See: Starting and Charging/Battery Vehicles with seat side air bags 20. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector. 21. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8098 22. Remove the tie-strap and disconnect the driver seat side air bag electrical connector. 23. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. All vehicles 24. Install the RCM fuse F2.6 (7.5A without rear blower, 15A with rear blower) to the CJB and close the cover. 25. Connect the battery ground cable. For additional See: Starting and Charging/Battery Reactivation Procedure Reactivation All vehicles 1. Turn the ignition switch to OFF. 2. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For additional information, refer to the wiring Diagram Manual. 3. Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, See: Starting and Charging/Battery Vehicles with seat side air bags 4. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8099 5. Connect the driver seat side air bag electrical connector and tie-strap the wire harness. 6. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical connector. 7. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. Vehicles with seat side air bags and power driver seat 8. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. For additional information, See: Starting and Charging/Battery Vehicles with seat side air bags 9. Position the front seats rearward. Vehicles with seat side air bags and power driver seat 10. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, refer to See: Starting and Charging/Battery All vehicles Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8100 11. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. 12. Position the passenger air bag module to the instrument panel (I/P) and connect the electrical connector. 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Position the passenger air bag module into the instrument panel. Route the wire harness as noted in removal. 14. Install the two screws. 15. Close the glove compartment door. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8101 16. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector at the top of the steering column. 17. Position the driver air bag module to the steering wheel. 1. Connect the driver air bag module electrical connector. 2. Position the driver air bag module to the steering wheel. 18. Install the two driver air bag module retaining bolts. 19. Install the two steering wheel back cover plugs. 20. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 21. Turn the ignition switch from OFF to ON. 22. Install the RCM fuse F2.6 (7.5A without rear blower, 15A with rear blower) to the CJB and close the cover. 23. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8102 Connect the battery ground cable. 24. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: -fail to light. -remain lit continuously. -flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. 25. Clear all continuous DTCs from the restraints control module using a scan tool. Seats Removed There are two deactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. WARNING: IF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS BEING SERVICED, THE SYSTEM MUST BE DEACTIVATED AND RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED. THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. NOTE: ^ Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Disconnect the battery ground cable. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the driver air bag module. 4. Attach a Restraint System Diagnostic Tool 418-F088 (105-R0012) to the clockspring side of the driver air bag module connector. 5. Remove the passenger air bag module. 6. Attach a Restraint System Diagnostic Tool 418-F088 (105-R0012) to the vehicle harness side of the passenger air bag connector. 7. If equipped with a front power driver seat, reconnect the battery ground cable. 8. Move and tilt the front seats to their highest and most forward position. 9. If equipped with a front power driver seat, disconnect the battery ground cable. 10. Remove the affected front seat(s). 11. Disconnect the passenger seat side air bag module electrical connector (if necessary) and attach Restraint System Diagnostic Tool 418-133 (40-009) to the vehicle harness side of the passenger seat side air bag module electrical connector. 12. Disconnect the driver seat side air bag module electrical connector (if necessary) and attach Restraint System Diagnostic Tool 418-133 (40-009) to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8103 the vehicle harness side of the driver seat side air bag module electrical connector. 13. Reconnect the battery ground cable. Seats Not Removed There are two deactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. WARNING: IF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS BEING SERVICED, THE SYSTEM MUST BE DEACTIVATED AND RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED. THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. NOTE: ^ Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Disconnect the battery ground cable. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the driver air bag module. 4. Attach a Restraint System Diagnostic Tool 418-F088 (105-R0012) to the clockspring side of the driver air bag module connector. 5. Remove the passenger air bag module. 6. Attach a Restraint System Diagnostic Tool 418-F088 (105-R0012) to the vehicle harness side of the passenger air bag connector. 7. If equipped with seat side air bags and a front power driver seat reconnect the battery ground cable. 8. Move and tilt the front seats to their highest and most forward position. 9. If equipped with seat side air bags and a front power driver seat, disconnect the battery ground cable. 10. If equipped with seat side air bags, disconnect the passenger seat side air bag module electrical connector and attach Restraint System Diagnostic Tool 418-133 (40-009) to the vehicle harness side of the passenger seat side air bag module electrical connector. CAUTION: Vehicles without side air bags, do not deactivate the side air bag module circuit by removing the side air bag bridge resistor from the side air bag floor connector. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM). If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. 11. If equipped with seat side air bags, disconnect the driver seat side air bag module electrical connector and attach Restraint System Diagnostic Tool 418-133 (40-009) to the vehicle harness side of the driver seat side air bag module electrical connector. CAUTION: Vehicles without side air bags, do not deactivate the side air bag module circuit by removing the side air bag bridge resistor from the side air bag floor connector. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8104 If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. 12. Reconnect the battery ground cable. Seats Removed There are two reactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES AND PRETENSIONERS MUST BE RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. 1. Move and tilt the front seats to their highest and most forward position. 2. Disconnect the battery ground cable. 3. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 4. Remove the restraint system diagnostic tool from the driver seat side air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. Remove the restraint system diagnostic tool from the passenger seat side air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 6. Install the affected front seat(s). 7. Connect the driver seat side air bag module electrical connectors. 8. Connect the passenger seat side air bag module electrical connectors. 9. If equipped with a front power driver seat, reconnect the battery ground cable. 10. Move the front seats rearward. 11. If equipped with a front power driver seat, disconnect the battery ground cable. 12. Remove the restraint system diagnostic tool from the passenger air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 13. Install the passenger air bag module. 14. Remove the restraint system diagnostic tool from the clockspring connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 15. Install the driver air bag module. 16. Reconnect the battery ground cable. 17. Prove out the system. Seats Not Removed There are two reactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES AND Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8105 PRETENSIONERS MUST BE RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. 1. If equipped with seat side air bags, move and tilt the front seats to their highest and most forward position. 2. Disconnect the battery ground cable. 3. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 4. If equipped with seat side air bags: 1 Remove the restraint system diagnostic tool from the driver seat side air bag module electrical connector. 2 Remove the restraint system diagnostic tool from the passenger seat side air bag module electrical connector. 3 Connect the driver seat side air bag module electrical connectors. 4 Connect the passenger seat side air bag module electrical connectors. 5 Reconnect the battery ground cable. 6 Move the front seats rearward. 7 Disconnect the battery ground cable. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. Remove the restraint system diagnostic tool from the passenger air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 6. Install the passenger air bag module. 7. Remove the restraint system diagnostic tool from the clockspring connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 8. Install the driver air bag module. 9. Reconnect the battery ground cable. 10. Prove out the system. Procedures For Repair Operations SPECIAL TOOL(S) DEACTIVATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8106 INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the air bag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the seat side air bag (if equipped) and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Remove the retaining screws and position the hood release handle out of the way. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8107 3. Remove the lower steering column opening finish panel. 1 Remove the two retaining screws from the lower steering column opening finish panel. 2 Pull out to release the retaining clips and remove the lower steering column opening finish panel. 4. Remove the bolts and the lower steering column opening finish panel reinforcement. 5. Disconnect the clockspring electrical connector at the base of the steering column. 6. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8108 7. Open the glove compartment door past its stops to access the mounting screws. 8. Remove the two screws. 9. Reaching one hand into the glove compartment opening, push out on the passenger air bag module and separate it from the instrument panel. Note the wire harness routing for installation. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. 10. Disconnect the electrical connector and remove the passenger air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8109 11. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. Vehicles without seat side air bags 12. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the Restraints Control Module (RCM). If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. CAUTION: Do not deactivate the side air bag module circuit be removing the side air bag bridge resistor from the side air bag to floor connector. Vehicles with seat side air bags and power driver seat 13. Connect the battery ground cable. Vehicles with seat side air bags 14. Move and tilt the front seats to their highest and most forward position. Vehicles with seat side air bags and power driver seat 15. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Vehicles with seat side air bags 16. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8110 17. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. 18. Remove the tie-strap and disconnect the driver seat side air bag electrical connector. 19. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. All vehicles 20. Connect the battery ground cable. 21. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). See: Prove Out Procedure 22. Disconnect the battery ground cable and wait at least one minute. REACTIVATION WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, CAUTIONS, AND NOTES AT THE BEGINNING OF THE DEACTIVATION PROCEDURE. Vehicles with seat side air bags Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8111 1. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical connector. NOTE: Make sure the battery ground cable is still disconnected before proceeding with the reactivation portion of this procedure. 2. Connect the driver seat side air bag electrical connector and tie-strap the wire harness. 3. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical connector. 4. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. Vehicles with seat side air bags and power driver seat 5. Connect the battery ground cable. Vehicles with seat side air bags 6. Position the front seats rearward. Vehicles with seat side air bags and power driver seat Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8112 7. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). All vehicles 8. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. 9. Position the passenger air bag module to the Instrument Panel (I/P) and connect the electrical connector. 10. Position the passenger air bag module into the instrument panel. Route the wire harness as noted in removal. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8113 11. In stall the two screws. 12. Close the glove compartment door. 13. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector at the base of the steering column. 14. Connect the clockspring electrical connector at the base of the steering column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8114 15. Position the lower steering column opening finish panel reinforcement and install the bolts. 16. Install the lower steering column opening finish panel. 1 Position the lower steering column opening finish panel to the I/P and push in at the top to seat the retaining clips. 2 Install the screws. 17. Position the hood release handle and install the screws. 18. Connect the battery ground cable. 19. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Prove Out Procedure WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 20. Check the active restraint system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8115 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag modules connected? 3. Is the Restraints Control Module (RCM) connected? 4. Is the vehicle battery connected? Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8116 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure Turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator with the air bag modules or restraint system diagnostic tools installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag Supplemental Restraint System (SRS) fault is present, the air bag indicator will either: ^ fail to light. ^ remain lit continuously. ^ flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the RUN position. This is the time required for the Restraints Control Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Page 8117 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Service Precautions > Technician Safety Information Air Bag Harness: Technician Safety Information WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE AND IN THE FRONT SEAT REMOVAL AND INSTALLATION PROCEDURE. Refer to Air Bag(s) Arming and Disarming. ^ INSPECT THE MOUNTING SURFACES OF THE SIDE AIR BAG MODULE AND THE SEAT BACK FRAME MOUNTING BRACKET FOR ANY FOREIGN OBJECTS BEFORE INSTALLING THE SIDE AIR BAG MODULE. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ INSPECT THE SIDE AIR BAG DEPLOYMENT CHUTE AND THE SIDE AIR BAG CAVITY IN THE SEAT BACK PAD FOR ANY FOREIGN OBJECTS. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ BEFORE INSTALLING THE SIDE AIR BAG MODULE, CHECK IT FOR DAMAGE AND FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ IF THE AIR BAG COVER HAS SEPARATED OR THE AIR BAG MATERIAL HAS BEEN EXPOSED, INSTALL A NEW SIDE AIR BAG MODULE. DO NOT ATTEMPT TO REPAIR THE AIR BAG MODULE. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE AND ZIPPER FOR DAMAGE. THE DEPLOYMENT CHUTE AND ZIPPER MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE TO THE DEPLOYMENT CHUTE OR ZIPPER THE SEAT BACK TRIM COVER AND DEPLOYMENT CHUTE MUST BE INSTALLED NEW AS A UNIT. ^ IF THE AIR BAG DEPLOYMENT CHUTE IS NOT PROPERLY POSITIONED AND COMPLETELY ZIPPED, THE SIDE AIR BAG MAY NOT DEPLOY PROPERLY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Service Precautions > Technician Safety Information > Page 8123 Air Bag Harness: Vehicle Damage Warnings CAUTION: ^ Use care when separating the seat cushion trim cover from the hook and loop strip. The hook and loop strip can be torn from the seat cushion foam. ^ Make sure the side air bag wiring harness is not pinched between the side air bag module and the mounting bracket. ^ The retaining nuts of the side air bag module must be tightened in the sequence described. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Service Precautions > Page 8124 Air Bag Harness: Service and Repair Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a side air bag deployment took place the seat back pad, trim cover and side air bag module must be replaced. The seat back frame should be replaced if necessary. ^ When replacing the side air bag after deployment, refer to Seats for additional information concerning the installation of a new side air bag. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Service Precautions > Page 8125 TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Deactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. Refer to Air Bag(s) Arming and Disarming. 3. Remove the front seat. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE FRONT SEAT REMOVAL AND INSTALLATION PROCEDURE. 4. Remove the front seat track. 5. Remove the front seat backrest. 6. Separate the seat back trim cover lower J-clip. 7. Remove and discard the hog rings from the two swing rods (one shown). 8. Slide the swing rods out of the seat back trim cover. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Service Precautions > Page 8126 9. Roll the seat back trim cover, in an inside out fashion, to the side air bag deployment chute. CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip. The hook and loop strip can be torn from the seat cushion foam. 10. Remove and discard the tie-strap holding the deployment chute tail and side air bag wire harness in place. 11. Unzip the side air bag deployment chute. 12. Roll the seat back cover and side air bag deployment chute to completely expose the side air bag module, mounting bracket and side air bag shield. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Service Precautions > Page 8127 13. Remove and discard the duct tape retaining the side air bag shield. 14. Separate the side air bag wiring harness pin-type retainers from the seat back frame. 15. Remove the side air bag stud covers. 16. Remove the side air bag module nuts. NOTE: If installing a new side air bag module, use new retaining nuts. If the same side air bag module is to be reused, then reuse the side air bag module retaining nuts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Service Precautions > Page 8128 17. Position the side air bag module and shield out through the seat back cushion opening. 18. Remove the side air bag module. 1 Slide the side air bag module electrical connector locking clip to disengage it. 2 Release the connector tabs by pushing in on them, then disconnect the side air bag module electrical connector. 3 Remove the side air bag module. 19. Remove the shield from the side air bag module. 20. Remove the side air bag wire harness from the seat backrest frame. INSTALLATION WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, CAUTIONS AND NOTES AT THE BEGINNING OF THE REMOVAL PROCEDURE. 1. Position the side air bag wire harness to the seat backrest frame. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Service Precautions > Page 8129 2. Install the shield onto the side air bag module. 3. Connect the side air bag module electrical connector. 1 Install the connector to the side air bag module. 2 Slide the side air bag module electrical connector locking clip to secure the connector to the side air bag module. 4. Make sure the electrical connector is securely fastened to the side air bag module. 5. Position the side air bag module and shield into the seat backrest cushion. WARNING: ^ INSPECT THE MOUNTING SURFACES OF THE SIDE AIR BAG MODULE AND THE SEAT BACK FRAME MOUNTING BRACKET FOR ANY FOREIGN OBJECTS BEFORE INSTALLING THE SIDE AIR BAG MODULE. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ INSPECT THE SIDE AIR BAG DEPLOYMENT CHUTE AND THE SIDE AIR BAG CAVITY IN THE SEAT BACK PAD FOR ANY FOREIGN OBJECTS. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ BEFORE INSTALLING THE SIDE AIR BAG MODULE, CHECK IT FOR DAMAGE AND FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ IF THE AIR BAG COVER HAS SEPARATED OR THE AIR BAG MATERIAL HAS BEEN EXPOSED, INSTALL A NEW SIDE AIR BAG MODULE. DO NOT ATTEMPT TO REPAIR THE AIR BAG MODULE. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE AND ZIPPER FOR DAMAGE. THE DEPLOYMENT CHUTE AND ZIPPER MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE TO THE DEPLOYMENT CHUTE OR ZIPPER THE SEAT BACK TRIM COVER AND DEPLOYMENT CHUTE MUST BE INSTALLED NEW AS A UNIT. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Service Precautions > Page 8130 6. Position the side air bag module studs, with the shield still in place, through the seat backrest mounting bracket holes. ^ Do not pinch the side air bag module wiring harness between the side air bag module and the mounting bracket. CAUTION: Make sure the side air bag wiring harness is not pinched between the side air bag module and the mounting bracket. 7. Route the side air bag module wire harness and install the side air bag nuts and tighten in the sequence shown. 1 Route the side air bag module wire harness to the back side of the side air bag mounting bracket making sure it is not pinched between the side air bag module and the mounting bracket. 2 Install the side air bag nuts. CAUTION: ^ The retaining nuts of the side air bag module must be tightened in the sequence described. ^ Make sure the side air bag wiring harness is not pinched between the side air bag module and the mounting bracket. 8. Install the side air bag stud covers. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Service Precautions > Page 8131 9. Position the side air bag shield to the seat backrest frame. 1 Apply new duct tape to the side air bag shield. 2 Position the side air bag module wire harness so that it will fit loosely between the side air bag shield and the mounting bracket. 3 Position the side air bag shield to the seat backrest frame keeping it in place with the tape. ^ Check that the side air bag module wire harness fits loosely between the side air bag shield and the mounting bracket and is not pinched. 10. Route the side air bag wire harness and install the pin-type retainers to the seat back frame. 11. Unroll the seat back trim cover to position the deployment chute around the side air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Service Precautions > Page 8132 12. Position the air bag deployment chute. 1 Insert the outboard side of the air bag deployment chute between the seat back pad and the side air bag module, pulling it around the outboard side of the seat back frame. 2 Insert the inboard side of the air bag deployment chute between the seat back pad and the side air bag module from the inboard side of the seat back. WARNING: ^ CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE AND ZIPPER FOR DAMAGE. THE DEPLOYMENT CHUTE AND ZIPPER MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE TO THE DEPLOYMENT CHUTE OR ZIPPER THE SEAT BACK TRIM COVER AND DEPLOYMENT CHUTE MUST BE INSTALLED NEW AS A UNIT. ^ IF THE AIR BAG DEPLOYMENT CHUTE IS NOT PROPERLY POSITIONED AND COMPLETELY ZIPPED, THE SIDE AIR BAG MAY NOT DEPLOY PROPERLY. 13. Zip the air bag deployment chute completely closed, then position the zipper tail at the top of the deployment chute, into the seat back opening. ^ The side air bag deployment chute must encircle the side air bag module, going completely around the side air bag module and the side of the seat back frame. ^ Align the side air bag deployment chute to the side air bag module, making sure it covers the length of the side air bag module. NOTE: Be sure the side air bag deployment chute is properly positioned, before proceeding. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Service Precautions > Page 8133 14. Position the deployment chute tail and side air bag wire harness and tie-strap them in place. 15. Unroll the seat back trim cover to the bottom row of hog rings. 16. Install the swing rods back into the seat back trim cover sleeves. 17. Reaching between the seat back trim cover and the seat back pad, at the middle row of hog rings, position the top of the swing rods under the listing wire in the seat back pad. NOTE: The seat back trim cover has been inverted for clarity. 18. Install new hog rings onto the swing rods (one shown). 19. Pull the seat backrest trim cover completely down and connect the hook and loop fastener to the seat back cushion. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Service Precautions > Page 8134 20. Reattach the seat hack trim cover lower J-clips. 21. Install the front seat backrest. 22. Install the front seat track. 23. Install the front seat. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE FRONT SEAT REMOVAL AND INSTALLATION PROCEDURE. 24. Reactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. Refer to Air Bag(s) Arming and Disarming. 25. With all the diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 26. Check the active restraint system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Service Precautions > Page 8135 Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs Air Bag Control Module: Technical Service Bulletins Restraints - Control Module DTCs & Associated Fault PIDs TSB 07-12-3 06/25/07 RCM FAULT REPORTING USING DTCS AND BIT-MAPPED PARAMETER IDENTIFIERS (PIDS) - SERVICE TIPS FORD: 2001-2007 Crown Victoria 2002-2007 Taurus 2004-2007 Focus 2005-2007 Five Hundred, Freestyle, Mustang 2006-2007 Fusion 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac 2002-2003 Windstar 2002-2007 Explorer 2003-2007 Expedition 2004-2007 F-150, Freestar 2005-2007 Escape Hybrid, Escape 2007 E-Series LINCOLN: 2001-2007 Town Car 2003-2006 Lincoln LS 2006 Zephyr 2007 MKZ 2003-2005 Aviator 2003-2007 Navigator 2006-2007 Mark LT MERCURY: 2001-2007 Grand Marquis 2002-2005 Sable 2005-2007 Montego 2006-2007 Milan 2002-2007 Mountaineer 2004-2007 Monterey 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 07-7-8 to update the vehicle application. ISSUE Various 2001-2007 vehicles are equipped with a restraints control module (RCM) that report diagnostic trouble codes (DTCs) which provide general fault information. These DTCs require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific fault. Most 2001-2006 Workshop Manuals (WSM) were written using New Generation STAR Tester (NGS) terminology and navigation which does not translate well when using Integrated Diagnostic System (IDS), Portable Diagnostic Software (PDS) or Worldwide Diagnostic System (WDS). ACTION Refer to the Service Tips to assist with navigation of both the WSM and the scan tool being used. SERVICE TIPS DTCs And Associated Fault PIDs Description Many of the continuous memory and on-demand DTCs that can be present in the RCM provide general fault information and require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific concern. DTCs that use fault PIDs are conceptually different from conventional DTCs. Conventional DTCs identify a specific concern for a given component and point to a particular diagnostic path. In the diagnostic path, PIDs are sometimes used to determine the root cause. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8140 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8141 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8142 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8143 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8144 DTCs that use fault PIDs do not identify the specific concern. The DTC identifies the component(s) or type of component(s) in which the concern exists. The next level, fault PIDs, identifies the specific device and fault condition. Fault PIDs are available for both on-demand (active) and continuous memory (historic or intermittent) DTCs. A scan tool must be used to view the DTCs and their fault PIDs. The table lists those DTCs that are supported by associated fault PIDs. (Figures 1-5) VIEWING FAULT PIDS USING SCAN TOOLS WSM Direction to FLAG DTC/View Fault PIDs The information in viewing fault PIDs in the WSM has evolved over the years as the scan tools have transitioned. Examples of how the WSM may direct you to view fault PIDs are: ^ FLAG DTC XXXXX/Record All Flagged Faults (2001-2006 WS Ms) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8145 ^ View and Record DTC XXXXX Fault PIDs (2007 WSM) ^ DataLogger/View and Record DTC XXXXX Fault Pids (2008 and future WSMs) In each instance the direction is the same (view fault PIDs to identify the specific component and fault condition) but how they are accessed by the scan tools, as well as the scan tool terminology, will vary. FLAG the DTC - View the Fault PIDs For example, the "Flag" DTC feature is specific to NGS/NGS+. When using IDS/PDS it is necessary to view the fault PIDs from DataLogger. Using IDS/PDS NOTE WHEN USING IDS/PDS, MOVE THE CURSOR OVER THE PID OR SELECT THE PID TO DISPLAY ITS DEFINITION AT THE BOTTOM OF THE SCREEN. WHEN USING PDS, HIGHLIGHT OR MOVE THE STYLUS OVER THE PID TO SEE THE PID DEFINITION. 1. Perform a self test of the RCM and/or OCS module to retrieve on-demand and continuous memory DTCs. 2. To view the fault PIDs associated with an on-demand DTC: a. Toolbox b. DataLogger c. Modules d. RCM 3. Monitor all "_OD" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". ^ For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_OD PID reads "FAULT' indicating a front internal crash sensor fault. 4. To view the fault PIDs associated with a continuous memory DTC: a. Toolbox b. DataLogger c. Modules d. RCM 5. Monitor all "_CM" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_CM PID reads "FAULT" indicating a front internal crash sensor fault. IDS/PDS Fault PID Naming Conventions The fault PIDs as displayed on IDS/PDS uses a strategy associating it with the DTC. For example, the fault PIDs 2296_18_OD and 2296_18_CM break down as follows: ^ 2296 - The DTC number minus the "B" (body) or "C" (chassis) designation. ^ 18 - An identifier used to distinguish between each of the fault PIDs associated with the DTC. ^ OD - Identifies the fault PID as an on-demand fault. ^ CM - Identifies the fault PID as a continuous memory (intermittent) fault. NOTE THE DTCS AND FAULT PIDS SUPPORTED BY A VEHICLE WILL VARY DEPENDING ON VEHICLE EQUIPMENT. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8146 Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5) WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 8147 Torque Specifications Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 8148 View 151-9 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 8149 Air Bag Control Module: Diagrams Connector View C2041a Connector View C2041b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service Precautions > Technician Safety Information Air Bag Control Module: Technician Safety Information WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE AND AT THE BEGINNING OF THE REMOVAL PROCEDURE. Refer to Air Bag(s) Arming and Disarming. ^ THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service Precautions > Technician Safety Information > Page 8152 Air Bag Control Module: Vehicle Damage Warnings CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service Precautions > Page 8153 Air Bag Control Module: Description and Operation The Restraints Control Module (RCM) carries out the following functions: ^ signals the inflators to deploy the air bags in the event of a deployable crash. ^ monitors the air bag Supplemental Restraint System (SRS) for faults. ^ illuminates the air bag indicator if a fault is detected. ^ flashes the air bag indicator to indicate the Lamp Fault Code (LFC) detected. ^ communicates through the Data Link Connector (DLC) the current or historical Diagnostic Trouble Codes (DTCs). ^ signals the Generic Electronic Module (GEM) to activate a chime if the air bag indicator is not available and another SRS fault exists. NOTE: The safety sensor is internal to the RCM and is not serviced separately. The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the RUN position, the RCM will flash the air bag indicator located in the instrument cluster. When the ignition is cycled (turned off and then on), the air bag indicator will prove out by lighting for six seconds and then off for two seconds. After the prove out, the air bag indicator will then flash the two-digit LFC for any current SRS fault. If an SRS fault exists, the air bag indicator will flash the LFC five times, and then remain illuminated for the rest of the key cycle. The RCM will also communicate the current and historical DTCs through the DLC, to the scan tool. If the air bag indicator does not function, and the system detects a fault condition, the RCM will signal the GEM to activate an audible chime. The chime is a series of five sets of five tone bursts. If the chime is heard, the SRS and the air bag indicator require repair. LFCs are prioritized. If two or more faults occur at the same time, the fault having the highest priority will be displayed. After that fault has been corrected, the next highest priority fault will be displayed. The RCM includes a backup power supply. This feature provides sufficient backup power to deploy the air bags in the event that the ignition circuit is damaged in a collision before the safing and air bag sensors determine that a deployment is required. The backup power supply will deplete its stored energy approximately one minute after the battery ground cable is disconnected. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service Precautions > Page 8154 Air Bag Control Module: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Air Bag Systems; Testing and Inspection. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module (RCM) Air Bag Control Module: Service and Repair Restraints Control Module (RCM) SPECIAL TOOL(S) REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. All vehicles 1. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Deactivate the Supplemental Restraint System (SRS). Refer to Air Bag(s) Arming and Disarming. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. Refer to Air Bag(s) Arming and Disarming. Vehicles with seat side air bags and power driver seat 3. Connect the battery ground cable. Vehicles with seat side air bags 4. Move the front seats rearward. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module (RCM) > Page 8157 Vehicles with seat side air bags and power driver seat 5. Disconnect the battery ground cable and wait at least one minute. Vehicles with full floor console 6. Remove the full floor console. Vehicles with a restraints control module cover 7. Remove the mat, the screws and the Restraints Control Module (RCM) cover. All vehicles 8. Remove the right-hand side RCM retaining bolts. 9. Remove the RCM. 1 Slide and disengage the two RCM electrical connector locking clips. 2 Push down to pivot the RCM electrical connector tabs and pull out to disconnect. 3 Remove the retaining bolt. 4 Remove the RCM. INSTALLATION WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, CAUTIONS AND NOTES AT THE BEGINNING OF THE REMOVAL PROCEDURE. All vehicles 1. Position the RCM to the center tunnel area and install the three bolts hand-tight. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module (RCM) > Page 8158 NOTE: Make sure the battery ground cable is still disconnected before proceeding with the installation portion of this procedure. 2. Tighten the right-hand side RCM bolts to specification. WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 3. Connect the RCM. 1 Tighten the bolt to specification. 2 Connect the RCM electrical connectors. 3 Slide and engage the RCM electrical connector locking clips. WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 4. Connect the battery ground cable. 5. With the restraint system diagnostic tools still installed at all deployable devices, prove out the air bag system. See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 6. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Vehicles with full floor console 7. Install the full floor console. Vehicles with a restraint control module cover Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module (RCM) > Page 8159 8. Position the RCM cover. Install the screws and the mat. Vehicles with seat side air bags and power driver seat 9. Connect the battery ground cable. Vehicles with seat side air bags 10. Move and tilt the front seats to their highest and most forward position. Vehicles with seat side air bags and power driver seat 11. Disconnect the battery ground cable and wait at least one minute. All vehicles 12. Reactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. Refer to Air Bag(s) Arming and Disarming. 13. With all the diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module (RCM) > Page 8160 Air Bag Control Module: Service and Repair Weld Nut Repair "J" Nut, Restraints Control Module (RCM) and Side Impact Sensor WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both this procedures and Weld Nut Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Impact Sensor before proceeding with the repair. ^ If two or more weld nuts are missing, do not install the "J" nuts as outlined in this procedure. Weld nuts must be installed as outlined in Weld Nut Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Impact Sensor. ^ The following procedure applies to vehicles that have a rectangular hole in the sheet metal that is in close proximity to the missing weld nut. 1. Obtain a "J" nut (part number N623332-S301) or any of the following optional "J" nuts (part numbers: N623342-S101, N800854-S100, N800925-S100). 2. Obtain a 6 mm (0.24 in) grounding screw or equivalent. 3. Install the "J,' nut through the rectangular hole in the sheet metal. 4. Install the crash sensor. NOTE: Be sure the threaded portion of the "J" nut is aligned with the clearance hole in the sheet metal. 5. Tighten the attaching screws to specification. Refer to Torque Specifications. Missing Weld Nut, RCM and Side Impact Sensor WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both this procedure and Weld Nut Repair - "J" Nut, Restraints Control Module (RCM) and Side Impact Sensor before proceeding with the repair. ^ Use only this procedure if two or more weld nuts are missing, do not install the "J" nuts as outlined in Weld Nut Repair - "J" Nut, Restraints Control Module (RCM) and Side Crash Sensor. ^ Radiator support repair shown, others are similar. 1. Obtain a 6 mm (0.24 in) weld nut. 2. Obtain a 6 mm (0.24 in) grounding screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module (RCM) > Page 8161 3. Route a sufficient length of copper welding wire through the weld nut clearance hole and back out an adjacent access hole. 4. Feed the copper welding wire through the weld nut, then through a standard flat washer. 5. Secure the flat washer so that it cannot he pulled off the end of the copper welding wire. 6. Pull the copper welding wire back through the clearance hole, allowing the weld nut and flat washer to follow the copper welding wire through. 7. Position the weld nut to the weld nut clearance hole, firmly pulling on the copper welding wire allowing the secured flat washer to hold the weld nut in position. 8. Holding the weld nut securely in place and using a MIG welder, weld in four places around the edge of the weld nut. 9. Metal finish as required. 10. Verify the nut is securely in place. 11. In stall the crash sensor. 12. Tighten the attaching screws to specification. Refer to Torque Specifications. Stripped Weld Nut, RCM and Side Impact Sensor WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 1. Obtain an 8 mm (0.32 in) grounding screw. 2. Drill out the internal threads of the stripped-out weld nut to 7.37 mm (0.29 in) using a letter "L" size drill bit. 3. Position the crash sensor to the vehicle. 4. Install the 8 mm (0.32 in) grounding screw into the drilled-out weld nut. 5. Install the remaining attaching screws. 6. Tighten the attaching screws to specification. Refer to Torque Specifications. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Page 8162 Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Resistor > Component Information > Service Precautions Air Bag Resistor: Service Precautions WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, CAUTIONS AND NOTES AT THE BEGINNING OF THE REMOVAL PROCEDURE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Resistor > Component Information > Service and Repair > Side Air Bag Bridge Resistor - Driver Side Air Bag Resistor: Service and Repair Side Air Bag Bridge Resistor - Driver Side REMOVAL WARNING: ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Move and tilt the driver seat to its highest and most forward position. 2. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 3. Disconnect the driver seat side air bag bridge resistor electrical connector. 1 Remove the tie-strap. 2 Disconnect the driver seat side air bag bridge resistor electrical connector. 4. Remove the driver seat side air bag bridge resistor. 1 Push up to release the finger clip. 2 Slide the driver seat side air bag bridge resistor off the finger clip. INSTALLATION WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, CAUTIONS AND NOTES AT THE BEGINNING OF THE REMOVAL PROCEDURE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Resistor > Component Information > Service and Repair > Side Air Bag Bridge Resistor - Driver Side > Page 8168 1. Slide the driver seat side air bag bridge resistor onto the finger clip. 2. Connect the driver seat side air bag bridge resistor. 1 Connect the driver seat side air bag bridge resistor. 2 Tie-strap the wire harness in place. 3. Connect the battery ground cable. 4. Prove out the supplemental restraint system (SRS). See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Resistor > Component Information > Service and Repair > Side Air Bag Bridge Resistor - Driver Side > Page 8169 Air Bag Resistor: Service and Repair Side Air Bag Bridge Resistor - Passenger Side REMOVAL WARNING: ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Move the passenger seat to its most forward position. 3. Disconnect the passenger seat side air bag bridge resistor electrical connector. 1 Remove the tie-strap. 2 Disconnect the passenger seat side air bag bridge resistor electrical connector. 4. Remove the passenger seat side air bag bridge resistor. 1 Push up to release the finger clip. 2 Slide the passenger seat side air bag bridge resistor off the finger clip. INSTALLATION WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, CAUTIONS AND NOTES AT THE BEGINNING OF THE REMOVAL PROCEDURE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Resistor > Component Information > Service and Repair > Side Air Bag Bridge Resistor - Driver Side > Page 8170 1. Slide the passenger seat side air bag bridge resistor onto the finger clip. 2. Connect the passenger seat side air bag bridge resistor. 1 Connect the passenger seat side air bag bridge resistor. 2 Tie-strap the wire harness in place: 3. Connect the battery ground cable. 4. Prove out the supplemental restraint system (SRS). See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Diagrams Air Bag Sliding Contact: Diagrams Connector View C218a Connector View C218b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Service Precautions > Technician Safety Information Air Bag Sliding Contact: Technician Safety Information WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED TRIM COVERS MUST BE INSTALLED NEW, NOT REPAINTED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE AND IN THE STEERING WHEEL REMOVAL AND INSTALLATION PROCEDURE. ^ INCORRECT CENTRALIZATION MAY RESULT IN PREMATURE COMPONENT FAILURE. IF IN DOUBT WHEN CENTRALIZING THE CLOCKSPRING, REPEAT THE CENTRALIZING PROCEDURE. FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN PERSONAL INJURY. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Service Precautions > Technician Safety Information > Page 8176 Air Bag Sliding Contact: Vehicle Damage Warnings CAUTION: ^ Make sure the road wheels are in the straight-ahead position. ^ Overturning will destroy the clockspring. The internal ribbon wire acts as the stop and can be broken from its internal connection. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Service Precautions > Page 8177 Air Bag Sliding Contact: Description and Operation The clockspring: ^ is mounted on the steering column, behind the steering wheel. ^ provides a continuous electrical path between the Restraints Control Module (RCM) and the driver air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Service Precautions > Page 8178 Air Bag Sliding Contact: Service and Repair SPECIAL TOOL(S) REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED TRIM COVERS MUST BE INSTALLED NEW, NOT REPAINTED. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. All vehicles 1. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Deactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. Refer to Air Bag(s) Arming and Disarming. Vehicles with seat side air bags and power driver seat 3. Connect the battery ground cable. Vehicles with seat side air bags 4. Move the driver seat rearward. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Service Precautions > Page 8179 Vehicles with seat side air bags and power driver seat 5. Disconnect the battery ground cable and wait at least one minute. All vehicles 6. Remove the steering wheel. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, CAUTIONS AND NOTES IN THE STEERING WHEEL REMOVAL AND INSTALLATION PROCEDURE. NOTE: Make sure the wheels are in the straight-ahead position. 7. Loosen, but do not remove, the four steering column-to-instrument panel retaining bolts enough to remove the upper steering column shroud (two shown). Vehicles with tilt column 8. Remove the tilt wheel handle shank. All vehicles 9. Remove the lower steering column shroud. 1 Remove the three screws. 2 Remove the lower steering column shroud. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Service Precautions > Page 8180 10. Remove the ignition switch lock cylinder. 1 Position the ignition switch lock cylinder to the RUN position. 2 Using the suitable tool, push upward on the cylinder release tab while pulling the ignition switch lock cylinder outward. 11. Remove the upper steering column shroud. 12. Remove the Passive Anti-Theft System (PATS) transmitter. 1 Remove the PATS transmitter retaining screw. 2 Position the PATS transmitter out of the way. 13. Remove the key-in-ignition warning indicator switch. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Service Precautions > Page 8181 14. Disconnect the clockspring electrical connectors. 1 Remove the bolt and separate the ground wire. 2 Remove the clockspring electrical connectors from the instrument panel and disconnect the remaining clockspring electrical connector. 15. Remove the clockspring wire harness from the two holders (one shown). 16. Release the lower clockspring retaining clip. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Service Precautions > Page 8182 17. Remove the clockspring. 1 Release the remaining two clockspring retaining clips. 2 Remove the clockspring. INSTALLATION WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, CAUTIONS AND NOTES AT THE BEGINNING OF THE REMOVAL PROCEDURE. Vehicles receiving a new clockspring 1. Remove the key from the clockspring, holding the rotor in its centralized position. ^ Do not allow the clockspring rotor to turn. NOTE: A new clockspring is supplied in a centralized position and held there with a key. Vehicles needing clockspring recentering 2. Centralize the clockspring. 1 Hold the clockspring outer housing stationary. 2 Depress the clockspring locking tab to release the rotor. 3 While holding the clockspring locking tab into the released position, turn the rotor counterclockwise, carefully feeling for the ribbon wire to run out of length, and a slight resistance is felt. Stop turning at this point. CAUTION: Overturning will destroy the clockspring. The internal ribbon wire acts as the stop and can be broken from its internal connection. 4 While holding the clockspring locking tab in the released position, turn the rotor clockwise approximately 3 turns. This is the center point of Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Service Precautions > Page 8183 the clockspring. ^ Release the clockspring locking tab. Lock the rotor in the centralized position. WARNING: INCORRECT CENTRALIZATION MAY RESULT IN PREMATURE COMPONENT FAILURE. IF IN DOUBT WHEN CENTRALIZING THE CLOCKSPRING, REPEAT THE CENTRALIZING PROCEDURE. FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN PERSONAL INJURY. CAUTION: Make sure the road wheels are in the straight-ahead position. NOTE: If a clockspring has rotated out of center, follow through with this step. All vehicles 3. Position the clockspring onto the steering column shaft. 1 Align the clockspring onto the steering column shaft. 2 Slide the clockspring down the steering column shaft and lock the clips into place. 4. Engage the lower clockspring retaining clip into place. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Service Precautions > Page 8184 5. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector at the base of the steering column. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 6. Connect the clockspring electrical connectors. 1 Connect the two clockspring electrical connectors to the vehicle harness and install the electrical connector pin-type retainers to the bracket. 2 Position the ground wire and install the bolt. 7. Route the wire harness into the two holders (one shown). 8. Install the key-in-ignition warning indicator switch to the steering column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Service Precautions > Page 8185 9. Install the passive anti-theft system (PATS) transmitter. 1 Position the PATS transmitter to the steering column. 2 Install the PATS transmitter retaining screw. 10. Position the upper steering column shroud to the steering column. 11. Install the lower steering column shroud. 1 Position the lower steering column shroud to the steering column and the upper steering column shroud. 2 Install the screws. 12. Tighten the four steering column to instrument panel retaining bolts (two shown). Vehicles with tilt column Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Service Precautions > Page 8186 13. If equipped, install the tilt wheel handle and shank. All vehicles 14. Install the ignition switch lock cylinder. ^ Align and install the ignition switch lock cylinder to the steering column. ^ Position the ignition switch lock cylinder to the off position. 15. Install the steering wheel. NOTE: Make sure the wheels are in the straight-ahead position. 16. Attach the restraint system diagnostic tool to the clockspring electrical connector at the top of the steering column. 17. Connect the battery ground cable. 18. With the restraint system diagnostic tools installed at all deployable devices, prove out the air bag system. See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 19. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Service Precautions > Page 8187 THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 20. Position the lower steering column opening finish panel reinforcement and install the bolts. 21. Install the lower steering column opening finish panel. 1 Position the lower steering column opening finish panel to the I/P and push in at the top, seating the retaining clips. 2 Install the screws. 22. Position the hood release handle and install the screws. 23. Remove the restraint system diagnostic tool from the clockspring electrical connector at the top of the steering column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Service Precautions > Page 8188 WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 24. Position the driver air bag module to the steering wheel. 1 Connect the driver air bag module electrical connector. 2 Position the driver air bag module to the steering wheel. 25. Install the two driver air bag module retaining bolts. 26. Install the two steering wheel back cover plugs. Vehicles with seat side air bags and power driver seat 27. Connect the battery ground cable. Vehicles with seat side air bags 28. Move the driver seat rearward. Vehicles with seat side air bags and power driver seat 29. Disconnect the battery ground cable and wait at least one minute. All vehicles 30. Reactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. Refer to Air Bag(s) Arming and Disarming. 31. With all the restraint system diagnostic tools removed, prove out the air bag system. See: Air Bag(s) Arming and Disarming/Service and Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Service Precautions > Page 8189 Repair/Prove Out Procedure WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Service Precautions > Page 8190 Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Specifications Torque Specifications Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Right Connector View C304 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Right > Page 8196 Connector View C305 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service Precautions > Customer Safety Information Impact Sensor: Customer Safety Information WARNING: MOUNTING ORIENTATION OF THE IMPACT SENSORS AND THE RCM IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE RCM MOUNTING AREA FOR DEFORMATION. INSPECT THE IMPACT SENSOR MOUNTING AREA FOR DAMAGE. IF DAMAGED, THE RCM AND SENSORS MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE MOUNTING AREA OF THE RCM AND IMPACT SENSORS ARE RESTORED TO THE ORIGINAL PRODUCTION CONFIGURATION. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service Precautions > Customer Safety Information > Page 8199 Impact Sensor: Technician Safety Information WARNING: ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, CAUTIONS AND NOTES AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE AND AT THE BEGINNING OF THE REMOVAL PROCEDURE. Refer to Air Bag(s) Arming and Disarming. ^ THE TIGHTENING TORQUE OF THE AIR BAG SIDE IMPACT SENSOR RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service Precautions > Page 8200 Impact Sensor: Description and Operation WARNING: MOUNTING ORIENTATION OF THE IMPACT SENSORS AND THE RCM IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE RCM MOUNTING AREA FOR DEFORMATION. INSPECT THE IMPACT SENSOR MOUNTING AREA FOR DAMAGE. IF DAMAGED, THE RCM AND SENSORS MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE MOUNTING AREA OF THE RCM AND IMPACT SENSORS ARE RESTORED TO THE ORIGINAL PRODUCTION CONFIGURATION. The impact sensors provide data to the RCM for use in calculating impact severity. This is accomplished using various electrical and electro-mechanical sensors located throughout the vehicle. Side impact sensors are located on the LH and RH B-pillars. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation Impact Sensor: Service and Repair Removal and Installation Side Impact Sensor - Driver Side Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Deactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. Refer to Air Bag(s) Arming and Disarming. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8203 3. Remove the LH rear quarter trim panel. 4. Disengage the wire harness pin-type retainers from the B-pillar and position the wire harness out of the way. 5. Position the side impact sensor with the bracket away from the B-pillar. 1 Remove the bolts. 2 Position the side impact sensor with the bracket away from the B-pillar. 6. Remove the side impact sensor. 1 Disconnect the electrical connector. 2 Remove the side impact sensor. INSTALLATION WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, CAUTIONS AND NOTES AT THE BEGINNING OF THE REMOVAL PROCEDURE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8204 1. Connect the side impact sensor electrical connector. 1 Position the side impact sensor. 2 Connect the side impact sensor electrical connector. 2. Install the side impact sensor. 1 Position the side impact sensor with the bracket to the B-pillar. 2 Install the bolts. WARNING: THE TIGHTENING TORQUE OF THE AIR BAG SIDE IMPACT SENSOR RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 3. Connect the battery ground cable. 4. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 5. Disconnect the battery ground cable and wait at least one minute. 6. Route the wire harness and attach the pin-type retainers to the B-pillar. 7. Install the LH rear quarter trim panel. 8. Reactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. Refer to Air Bag(s) Arming and Disarming. 9. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8205 VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 10. Check the active restraint system for correct operation. Side Impact Sensor - Passenger Side Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Deactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. Refer to Air Bag(s) Arming and Disarming. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8206 3. Remove the RH rear quarter trim panel. 4. Disengage the wire harness pin-type retainers from the B-pillar and position the wire harness out of the way. 5. Position the side impact sensor with the bracket away from the B-pillar. 1 Remove the bolts. 2 Position the side impact sensor with the bracket away from the B-pillar. 6. Remove the side impact sensor. 1 Disconnect the electrical connector. 2 Remove the side impact sensor. INSTALLATION WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, CAUTIONS AND NOTES AT THE BEGINNING OF THE REMOVAL PROCEDURE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8207 1. Connect the side impact sensor electrical connector. 1 Position the side impact sensor. 2 Connect the side impact sensor electrical connector. 2. Install the side impact sensor. 1 Position the side impact sensor with the bracket to the B-pillar. 2 Install the bolts. WARNING: THE TIGHTENING TORQUE OF THE AIR BAG SIDE IMPACT SENSOR RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 3. Connect the battery ground cable. 4. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 5. Disconnect the battery ground cable and wait at least one minute. 6. Route the wire harness and attach the pin-type retainers to the B-pillar. 7. Install the RH rear quarter trim panel. 8. Reactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. Refer to Air Bag(s) Arming and Disarming. 9. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8208 VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 10. Check the active restraint system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8209 Impact Sensor: Service and Repair General Procedures "J" Nut, Restraints Control Module (RCM) and Side Impact Sensor WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both this procedures and Weld Nut Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Impact Sensor before proceeding with the repair. ^ If two or more weld nuts are missing, do not install the "J" nuts as outlined in this procedure. Weld nuts must be installed as outlined in Weld Nut Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Impact Sensor. ^ The following procedure applies to vehicles that have a rectangular hole in the sheet metal that is in close proximity to the missing weld nut. 1. Obtain a "J" nut (part number N623332-S301) or any of the following optional "J" nuts (part numbers: N623342-S101, N800854-S100, N800925-S100). 2. Obtain a 6 mm (0.24 in) grounding screw or equivalent. 3. Install the "J,' nut through the rectangular hole in the sheet metal. 4. Install the crash sensor. NOTE: Be sure the threaded portion of the "J" nut is aligned with the clearance hole in the sheet metal. 5. Tighten the attaching screws to specification. Refer to Torque Specifications. Missing Weld Nut, RCM and Side Impact Sensor WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both this procedure and Weld Nut Repair - "J" Nut, Restraints Control Module (RCM) and Side Impact Sensor before proceeding with the repair. ^ Use only this procedure if two or more weld nuts are missing, do not install the "J" nuts as outlined in Weld Nut Repair - "J" Nut, Restraints Control Module (RCM) and Side Crash Sensor. ^ Radiator support repair shown, others are similar. 1. Obtain a 6 mm (0.24 in) weld nut. 2. Obtain a 6 mm (0.24 in) grounding screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8210 3. Route a sufficient length of copper welding wire through the weld nut clearance hole and back out an adjacent access hole. 4. Feed the copper welding wire through the weld nut, then through a standard flat washer. 5. Secure the flat washer so that it cannot he pulled off the end of the copper welding wire. 6. Pull the copper welding wire back through the clearance hole, allowing the weld nut and flat washer to follow the copper welding wire through. 7. Position the weld nut to the weld nut clearance hole, firmly pulling on the copper welding wire allowing the secured flat washer to hold the weld nut in position. 8. Holding the weld nut securely in place and using a MIG welder, weld in four places around the edge of the weld nut. 9. Metal finish as required. 10. Verify the nut is securely in place. 11. In stall the crash sensor. 12. Tighten the attaching screws to specification. Refer to Torque Specifications. Stripped Weld Nut, RCM and Side Impact Sensor WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 1. Obtain an 8 mm (0.32 in) grounding screw. 2. Drill out the internal threads of the stripped-out weld nut to 7.37 mm (0.29 in) using a letter "L" size drill bit. 3. Position the crash sensor to the vehicle. 4. Install the 8 mm (0.32 in) grounding screw into the drilled-out weld nut. 5. Install the remaining attaching screws. 6. Tighten the attaching screws to specification. Refer to Torque Specifications. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Page 8211 Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Safing Sensor, Air Bag > Component Information > Description and Operation Safing Sensor: Description and Operation The safety sensor is internal to the RCM and is not serviced separately. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Diagrams > Side Air Bag Module, Right Connector View C337 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Diagrams > Side Air Bag Module, Right > Page 8219 Connector View C367 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service Precautions > Technician Safety Information Side Air Bag: Technician Safety Information WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE AND IN THE FRONT SEAT REMOVAL AND INSTALLATION PROCEDURE. Refer to Air Bag(s) Arming and Disarming. ^ INSPECT THE MOUNTING SURFACES OF THE SIDE AIR BAG MODULE AND THE SEAT BACK FRAME MOUNTING BRACKET FOR ANY FOREIGN OBJECTS BEFORE INSTALLING THE SIDE AIR BAG MODULE. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ INSPECT THE SIDE AIR BAG DEPLOYMENT CHUTE AND THE SIDE AIR BAG CAVITY IN THE SEAT BACK PAD FOR ANY FOREIGN OBJECTS. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ BEFORE INSTALLING THE SIDE AIR BAG MODULE, CHECK IT FOR DAMAGE AND FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ IF THE AIR BAG COVER HAS SEPARATED OR THE AIR BAG MATERIAL HAS BEEN EXPOSED, INSTALL A NEW SIDE AIR BAG MODULE. DO NOT ATTEMPT TO REPAIR THE AIR BAG MODULE. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE AND ZIPPER FOR DAMAGE. THE DEPLOYMENT CHUTE AND ZIPPER MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE TO THE DEPLOYMENT CHUTE OR ZIPPER THE SEAT BACK TRIM COVER AND DEPLOYMENT CHUTE MUST BE INSTALLED NEW AS A UNIT. ^ IF THE AIR BAG DEPLOYMENT CHUTE IS NOT PROPERLY POSITIONED AND COMPLETELY ZIPPED, THE SIDE AIR BAG MAY NOT DEPLOY PROPERLY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service Precautions > Technician Safety Information > Page 8222 Side Air Bag: Vehicle Damage Warnings CAUTION: ^ Use care when separating the seat cushion trim cover from the hook and loop strip. The hook and loop strip can be torn from the seat cushion foam. ^ Make sure the side air bag wiring harness is not pinched between the side air bag module and the mounting bracket. ^ The retaining nuts of the side air bag module must be tightened in the sequence described. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service Precautions > Page 8223 Side Air Bag: Description and Operation Air Bag Module - Driver Side NOTE: References to side air bag modules refer to the seat-mounted and not to the steering wheel or instrument panel mounted air bag components of the Supplemental Restraint System (SRS). The driver side air bag module: ^ has no separately repairable parts and is installed as an assembly. ^ is mounted in the driver seat back. Air Bag Module - Passenger Side NOTE: References to side air bag modules refer to the seat-mounted and not to the steering wheel or instrument panel mounted air bag components of the supplemental restraint system (SRS). The passenger side air bag module: ^ has no separately repairable parts and is installed as an assembly. ^ is mounted in the passenger seat back. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service Precautions > Page 8224 Side Air Bag: Service and Repair Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a side air bag deployment took place the seat back pad, trim cover and side air bag module must be replaced. The seatback frame should be replaced if necessary. ^ When replacing the side air bag after deployment, refer to Seats for additional information concerning the installation of a new side air bag. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service Precautions > Page 8225 TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Deactivate the Supplemental Restraint System (SRS). Refer to Air Bag(s) Arming and Disarming. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. Refer to Air Bag(s) Arming and Disarming. 3. Remove the front seat. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE FRONT SEAT REMOVAL AND INSTALLATION PROCEDURE. 4. Remove the front seat track. 5. Remove the front seat backrest. 6. Separate the seat back trim cover lower J-clip. 7. Remove and discard the hog rings from the two swing rods (one shown). 8. Slide the swing rods out of the seat back trim cover. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service Precautions > Page 8226 9. Roll the seat back trim cover, in an inside out fashion, to the side air bag deployment chute. CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip. The hook and loop strip can be torn from the seat cushion foam. 10. Remove and discard the tie-strap holding the deployment chute tail and side air bag wire harness in place. 11. Unzip the side air bag deployment chute. 12. Roll the seat back cover and side air bag deployment chute to completely expose the side air bag module, mounting bracket and side air bag shield. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service Precautions > Page 8227 13. Remove and discard the duct tape retaining the side air bag shield. 14. Separate the side air bag wiring harness pin-type retainers from the seat back frame. 15. Remove the side air bag stud covers. 16. Remove the side air bag module nuts. NOTE: If installing a new side air bag module, use new retaining nuts. If the same side air bag module is to be reused, then reuse the side air bag module retaining nuts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service Precautions > Page 8228 17. Position the side air bag module and shield out through the seat back cushion opening. 18. Remove the side air bag module. 1 Slide the side air bag module electrical connector locking clip to disengage it. 2 Release the connector tabs by pushing in on them, then disconnect the side air bag module electrical connector. 3 Remove the side air bag module. 19. Remove the shield from the side air bag module. INSTALLATION WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, CAUTIONS AND NOTES AT THE BEGINNING OF THE REMOVAL PROCEDURE. 1. Install the shield onto the side air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service Precautions > Page 8229 2. Connect the side air bag module electrical connector. 1 Install the connector to the side air bag module. 2 Slide the side air bag module electrical connector locking clip to secure the connector to the side air bag module. 3. Make sure the electrical connector is securely fastened to the side air bag module. 4. Position the side air bag module and shield into the seat backrest cushion. WARNING: ^ INSPECT THE MOUNTING SURFACES OF THE SIDE AIR BAG MODULE AND THE SEAT BACK FRAME MOUNTING BRACKET FOR ANY FOREIGN OBJECTS BEFORE INSTALLING THE SIDE AIR BAG MODULE. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ INSPECT THE SIDE AIR BAG DEPLOYMENT CHUTE AND THE SIDE AIR BAG CAVITY IN THE SEAT BACK PAD FOR ANY FOREIGN OBJECTS. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ BEFORE INSTALLING THE SIDE AIR BAG MODULE, CHECK IT FOR DAMAGE AND FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ IF THE AIR BAG COVER HAS SEPARATED OR THE AIR BAG MATERIAL HAS BEEN EXPOSED, INSTALL A NEW SIDE AIR BAG MODULE. DO NOT ATTEMPT TO REPAIR THE AIR BAG MODULE. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE AND ZIPPER FOR DAMAGE. THE DEPLOYMENT CHUTE AND ZIPPER MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE TO THE DEPLOYMENT CHUTE OR ZIPPER THE SEAT BACK TRIM COVER AND DEPLOYMENT CHUTE MUST BE INSTALLED NEW AS A UNIT. 5. Position the side air bag module studs, with the shield still in place, through the seat backrest mounting bracket holes. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service Precautions > Page 8230 ^ Do not pinch the side air bag module wiring harness between the side air bag module and the mounting bracket. CAUTION: Make sure the side air bag wiring harness is not pinched between the side air bag module and the mounting bracket. 6. Route the side air bag module wire harness. Install the side air bag nuts and tighten in the sequence shown. 1 Route the side air bag module wire harness to the back side of the side air bag mounting bracket making sure it is not pinched between the side air bag module and the mounting bracket. 2 Install the side air bag nuts. CAUTION: ^ The retaining nuts of the side air bag module must be tightened in the sequence described. ^ Make sure the side air bag wiring harness is not pinched between the side air bag module and the mounting bracket. 7. Install the side air bag stud covers. 8. Position the side air bag shield to the seat backrest frame. 1 Apply new duct tape to the side air bag shield. 2 Position the side air bag module wire harness so that it will fit loosely between the side air bag shield and the mounting bracket. 3 Position the side air bag shield to the seat backrest frame keeping it in place with the tape. ^ Check that the side air bag module wire harness fits loosely between the side air bag shield and the mounting bracket and is not pinched. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service Precautions > Page 8231 9. Route the side air bag wire harness and install the pin-type retainers to the seat back frame. 10. Unroll the seat back trim cover, to position the deployment chute around the side air bag module. 11. Position the air bag deployment chute. 1 Insert the outboard side of the air bag deployment chute between the seat back pad and the side air bag module, pulling it around the outboard side of the seat back frame. 2 Insert the inboard side of the air bag deployment chute between the seat back pad and the side air bag module from the inboard side of the seat back. WARNING: ^ CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE AND ZIPPER FOR DAMAGE. THE DEPLOYMENT CHUTE AND ZIPPER MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE TO THE DEPLOYMENT CHUTE OR ZIPPER THE SEAT BACK TRIM COVER AND DEPLOYMENT CHUTE MUST BE INSTALLED NEW AS A UNIT. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service Precautions > Page 8232 ^ IF THE AIR BAG DEPLOYMENT CHUTE IS NOT PROPERLY POSITIONED AND COMPLETELY ZIPPED, THE SIDE AIR BAG MAY NOT DEPLOY PROPERLY. 12. Zip the air bag deployment chute completely closed, then position the zipper tail at the top of the deployment chute, into the seat back opening. ^ The side air bag deployment chute must encircle the side air bag module, going completely around the side air bag module and the side of the seat back frame. Align the side air bag deployment chute to the side air bag module, making sure it covers the length of the side air bag module. NOTE: Be sure the side air bag deployment chute is correctly positioned, before proceeding. 13. Position the deployment chute tail and side air bag wire harness and tie-strap them in place. 14. Unroll the seat back trim cover to the bottom row of hog rings. 15. Install the swing rods back into the seat back trim cover sleeves. 16. Reaching between the seat back trim cover and the seat back pad, at the middle row of hog rings, position the top of the swing rods under the Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service Precautions > Page 8233 listing wire in the seat back pad. NOTE: The seat back trim cover has been inverted for clarity. 17. Install new hog rings onto the swing rods (one shown). 18. Pull the seat back rest trim cover completely down and connect the hook and loop fastener to the seat back cushion. 19. Reattach the seat back trim cover lower J-clips. 20. Install the front seat backrest. 21. Install the front seat track. 22. Install the front seat. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE FRONT SEAT REMOVAL AND INSTALLATION PROCEDURE. 23. Reactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. Refer to Air Bag(s) Arming and Disarming. 24. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 25. Check the active restraint system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service Precautions > Page 8234 Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs Air Bag Control Module: Technical Service Bulletins Restraints - Control Module DTCs & Associated Fault PIDs TSB 07-12-3 06/25/07 RCM FAULT REPORTING USING DTCS AND BIT-MAPPED PARAMETER IDENTIFIERS (PIDS) - SERVICE TIPS FORD: 2001-2007 Crown Victoria 2002-2007 Taurus 2004-2007 Focus 2005-2007 Five Hundred, Freestyle, Mustang 2006-2007 Fusion 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac 2002-2003 Windstar 2002-2007 Explorer 2003-2007 Expedition 2004-2007 F-150, Freestar 2005-2007 Escape Hybrid, Escape 2007 E-Series LINCOLN: 2001-2007 Town Car 2003-2006 Lincoln LS 2006 Zephyr 2007 MKZ 2003-2005 Aviator 2003-2007 Navigator 2006-2007 Mark LT MERCURY: 2001-2007 Grand Marquis 2002-2005 Sable 2005-2007 Montego 2006-2007 Milan 2002-2007 Mountaineer 2004-2007 Monterey 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 07-7-8 to update the vehicle application. ISSUE Various 2001-2007 vehicles are equipped with a restraints control module (RCM) that report diagnostic trouble codes (DTCs) which provide general fault information. These DTCs require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific fault. Most 2001-2006 Workshop Manuals (WSM) were written using New Generation STAR Tester (NGS) terminology and navigation which does not translate well when using Integrated Diagnostic System (IDS), Portable Diagnostic Software (PDS) or Worldwide Diagnostic System (WDS). ACTION Refer to the Service Tips to assist with navigation of both the WSM and the scan tool being used. SERVICE TIPS DTCs And Associated Fault PIDs Description Many of the continuous memory and on-demand DTCs that can be present in the RCM provide general fault information and require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific concern. DTCs that use fault PIDs are conceptually different from conventional DTCs. Conventional DTCs identify a specific concern for a given component and point to a particular diagnostic path. In the diagnostic path, PIDs are sometimes used to determine the root cause. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8240 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8241 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8242 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8243 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8244 DTCs that use fault PIDs do not identify the specific concern. The DTC identifies the component(s) or type of component(s) in which the concern exists. The next level, fault PIDs, identifies the specific device and fault condition. Fault PIDs are available for both on-demand (active) and continuous memory (historic or intermittent) DTCs. A scan tool must be used to view the DTCs and their fault PIDs. The table lists those DTCs that are supported by associated fault PIDs. (Figures 1-5) VIEWING FAULT PIDS USING SCAN TOOLS WSM Direction to FLAG DTC/View Fault PIDs The information in viewing fault PIDs in the WSM has evolved over the years as the scan tools have transitioned. Examples of how the WSM may direct you to view fault PIDs are: ^ FLAG DTC XXXXX/Record All Flagged Faults (2001-2006 WS Ms) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8245 ^ View and Record DTC XXXXX Fault PIDs (2007 WSM) ^ DataLogger/View and Record DTC XXXXX Fault Pids (2008 and future WSMs) In each instance the direction is the same (view fault PIDs to identify the specific component and fault condition) but how they are accessed by the scan tools, as well as the scan tool terminology, will vary. FLAG the DTC - View the Fault PIDs For example, the "Flag" DTC feature is specific to NGS/NGS+. When using IDS/PDS it is necessary to view the fault PIDs from DataLogger. Using IDS/PDS NOTE WHEN USING IDS/PDS, MOVE THE CURSOR OVER THE PID OR SELECT THE PID TO DISPLAY ITS DEFINITION AT THE BOTTOM OF THE SCREEN. WHEN USING PDS, HIGHLIGHT OR MOVE THE STYLUS OVER THE PID TO SEE THE PID DEFINITION. 1. Perform a self test of the RCM and/or OCS module to retrieve on-demand and continuous memory DTCs. 2. To view the fault PIDs associated with an on-demand DTC: a. Toolbox b. DataLogger c. Modules d. RCM 3. Monitor all "_OD" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". ^ For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_OD PID reads "FAULT' indicating a front internal crash sensor fault. 4. To view the fault PIDs associated with a continuous memory DTC: a. Toolbox b. DataLogger c. Modules d. RCM 5. Monitor all "_CM" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_CM PID reads "FAULT" indicating a front internal crash sensor fault. IDS/PDS Fault PID Naming Conventions The fault PIDs as displayed on IDS/PDS uses a strategy associating it with the DTC. For example, the fault PIDs 2296_18_OD and 2296_18_CM break down as follows: ^ 2296 - The DTC number minus the "B" (body) or "C" (chassis) designation. ^ 18 - An identifier used to distinguish between each of the fault PIDs associated with the DTC. ^ OD - Identifies the fault PID as an on-demand fault. ^ CM - Identifies the fault PID as a continuous memory (intermittent) fault. NOTE THE DTCS AND FAULT PIDS SUPPORTED BY A VEHICLE WILL VARY DEPENDING ON VEHICLE EQUIPMENT. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8246 Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5) WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 8247 Torque Specifications Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 8248 View 151-9 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 8249 Air Bag Control Module: Diagrams Connector View C2041a Connector View C2041b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Technician Safety Information Air Bag Control Module: Technician Safety Information WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE AND AT THE BEGINNING OF THE REMOVAL PROCEDURE. Refer to Air Bag(s) Arming and Disarming. ^ THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Technician Safety Information > Page 8252 Air Bag Control Module: Vehicle Damage Warnings CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Page 8253 Air Bag Control Module: Description and Operation The Restraints Control Module (RCM) carries out the following functions: ^ signals the inflators to deploy the air bags in the event of a deployable crash. ^ monitors the air bag Supplemental Restraint System (SRS) for faults. ^ illuminates the air bag indicator if a fault is detected. ^ flashes the air bag indicator to indicate the Lamp Fault Code (LFC) detected. ^ communicates through the Data Link Connector (DLC) the current or historical Diagnostic Trouble Codes (DTCs). ^ signals the Generic Electronic Module (GEM) to activate a chime if the air bag indicator is not available and another SRS fault exists. NOTE: The safety sensor is internal to the RCM and is not serviced separately. The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the RUN position, the RCM will flash the air bag indicator located in the instrument cluster. When the ignition is cycled (turned off and then on), the air bag indicator will prove out by lighting for six seconds and then off for two seconds. After the prove out, the air bag indicator will then flash the two-digit LFC for any current SRS fault. If an SRS fault exists, the air bag indicator will flash the LFC five times, and then remain illuminated for the rest of the key cycle. The RCM will also communicate the current and historical DTCs through the DLC, to the scan tool. If the air bag indicator does not function, and the system detects a fault condition, the RCM will signal the GEM to activate an audible chime. The chime is a series of five sets of five tone bursts. If the chime is heard, the SRS and the air bag indicator require repair. LFCs are prioritized. If two or more faults occur at the same time, the fault having the highest priority will be displayed. After that fault has been corrected, the next highest priority fault will be displayed. The RCM includes a backup power supply. This feature provides sufficient backup power to deploy the air bags in the event that the ignition circuit is damaged in a collision before the safing and air bag sensors determine that a deployment is required. The backup power supply will deplete its stored energy approximately one minute after the battery ground cable is disconnected. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service Precautions > Page 8254 Air Bag Control Module: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Air Bag Systems; Testing and Inspection. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module (RCM) Air Bag Control Module: Service and Repair Restraints Control Module (RCM) SPECIAL TOOL(S) REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. All vehicles 1. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Deactivate the Supplemental Restraint System (SRS). Refer to Air Bag(s) Arming and Disarming. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. Refer to Air Bag(s) Arming and Disarming. Vehicles with seat side air bags and power driver seat 3. Connect the battery ground cable. Vehicles with seat side air bags 4. Move the front seats rearward. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module (RCM) > Page 8257 Vehicles with seat side air bags and power driver seat 5. Disconnect the battery ground cable and wait at least one minute. Vehicles with full floor console 6. Remove the full floor console. Vehicles with a restraints control module cover 7. Remove the mat, the screws and the Restraints Control Module (RCM) cover. All vehicles 8. Remove the right-hand side RCM retaining bolts. 9. Remove the RCM. 1 Slide and disengage the two RCM electrical connector locking clips. 2 Push down to pivot the RCM electrical connector tabs and pull out to disconnect. 3 Remove the retaining bolt. 4 Remove the RCM. INSTALLATION WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, CAUTIONS AND NOTES AT THE BEGINNING OF THE REMOVAL PROCEDURE. All vehicles 1. Position the RCM to the center tunnel area and install the three bolts hand-tight. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module (RCM) > Page 8258 NOTE: Make sure the battery ground cable is still disconnected before proceeding with the installation portion of this procedure. 2. Tighten the right-hand side RCM bolts to specification. WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 3. Connect the RCM. 1 Tighten the bolt to specification. 2 Connect the RCM electrical connectors. 3 Slide and engage the RCM electrical connector locking clips. WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 4. Connect the battery ground cable. 5. With the restraint system diagnostic tools still installed at all deployable devices, prove out the air bag system. See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 6. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Vehicles with full floor console 7. Install the full floor console. Vehicles with a restraint control module cover Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module (RCM) > Page 8259 8. Position the RCM cover. Install the screws and the mat. Vehicles with seat side air bags and power driver seat 9. Connect the battery ground cable. Vehicles with seat side air bags 10. Move and tilt the front seats to their highest and most forward position. Vehicles with seat side air bags and power driver seat 11. Disconnect the battery ground cable and wait at least one minute. All vehicles 12. Reactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. Refer to Air Bag(s) Arming and Disarming. 13. With all the diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module (RCM) > Page 8260 Air Bag Control Module: Service and Repair Weld Nut Repair "J" Nut, Restraints Control Module (RCM) and Side Impact Sensor WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both this procedures and Weld Nut Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Impact Sensor before proceeding with the repair. ^ If two or more weld nuts are missing, do not install the "J" nuts as outlined in this procedure. Weld nuts must be installed as outlined in Weld Nut Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Impact Sensor. ^ The following procedure applies to vehicles that have a rectangular hole in the sheet metal that is in close proximity to the missing weld nut. 1. Obtain a "J" nut (part number N623332-S301) or any of the following optional "J" nuts (part numbers: N623342-S101, N800854-S100, N800925-S100). 2. Obtain a 6 mm (0.24 in) grounding screw or equivalent. 3. Install the "J,' nut through the rectangular hole in the sheet metal. 4. Install the crash sensor. NOTE: Be sure the threaded portion of the "J" nut is aligned with the clearance hole in the sheet metal. 5. Tighten the attaching screws to specification. Refer to Torque Specifications. Missing Weld Nut, RCM and Side Impact Sensor WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both this procedure and Weld Nut Repair - "J" Nut, Restraints Control Module (RCM) and Side Impact Sensor before proceeding with the repair. ^ Use only this procedure if two or more weld nuts are missing, do not install the "J" nuts as outlined in Weld Nut Repair - "J" Nut, Restraints Control Module (RCM) and Side Crash Sensor. ^ Radiator support repair shown, others are similar. 1. Obtain a 6 mm (0.24 in) weld nut. 2. Obtain a 6 mm (0.24 in) grounding screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Restraints Control Module (RCM) > Page 8261 3. Route a sufficient length of copper welding wire through the weld nut clearance hole and back out an adjacent access hole. 4. Feed the copper welding wire through the weld nut, then through a standard flat washer. 5. Secure the flat washer so that it cannot he pulled off the end of the copper welding wire. 6. Pull the copper welding wire back through the clearance hole, allowing the weld nut and flat washer to follow the copper welding wire through. 7. Position the weld nut to the weld nut clearance hole, firmly pulling on the copper welding wire allowing the secured flat washer to hold the weld nut in position. 8. Holding the weld nut securely in place and using a MIG welder, weld in four places around the edge of the weld nut. 9. Metal finish as required. 10. Verify the nut is securely in place. 11. In stall the crash sensor. 12. Tighten the attaching screws to specification. Refer to Torque Specifications. Stripped Weld Nut, RCM and Side Impact Sensor WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 1. Obtain an 8 mm (0.32 in) grounding screw. 2. Drill out the internal threads of the stripped-out weld nut to 7.37 mm (0.29 in) using a letter "L" size drill bit. 3. Position the crash sensor to the vehicle. 4. Install the 8 mm (0.32 in) grounding screw into the drilled-out weld nut. 5. Install the remaining attaching screws. 6. Tighten the attaching screws to specification. Refer to Torque Specifications. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Page 8262 Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs Seat Belt Control Module: Technical Service Bulletins Restraints - Control Module DTCs & Associated Fault PIDs TSB 07-12-3 06/25/07 RCM FAULT REPORTING USING DTCS AND BIT-MAPPED PARAMETER IDENTIFIERS (PIDS) - SERVICE TIPS FORD: 2001-2007 Crown Victoria 2002-2007 Taurus 2004-2007 Focus 2005-2007 Five Hundred, Freestyle, Mustang 2006-2007 Fusion 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac 2002-2003 Windstar 2002-2007 Explorer 2003-2007 Expedition 2004-2007 F-150, Freestar 2005-2007 Escape Hybrid, Escape 2007 E-Series LINCOLN: 2001-2007 Town Car 2003-2006 Lincoln LS 2006 Zephyr 2007 MKZ 2003-2005 Aviator 2003-2007 Navigator 2006-2007 Mark LT MERCURY: 2001-2007 Grand Marquis 2002-2005 Sable 2005-2007 Montego 2006-2007 Milan 2002-2007 Mountaineer 2004-2007 Monterey 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 07-7-8 to update the vehicle application. ISSUE Various 2001-2007 vehicles are equipped with a restraints control module (RCM) that report diagnostic trouble codes (DTCs) which provide general fault information. These DTCs require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific fault. Most 2001-2006 Workshop Manuals (WSM) were written using New Generation STAR Tester (NGS) terminology and navigation which does not translate well when using Integrated Diagnostic System (IDS), Portable Diagnostic Software (PDS) or Worldwide Diagnostic System (WDS). ACTION Refer to the Service Tips to assist with navigation of both the WSM and the scan tool being used. SERVICE TIPS DTCs And Associated Fault PIDs Description Many of the continuous memory and on-demand DTCs that can be present in the RCM provide general fault information and require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific concern. DTCs that use fault PIDs are conceptually different from conventional DTCs. Conventional DTCs identify a specific concern for a given component and point to a particular diagnostic path. In the diagnostic path, PIDs are sometimes used to determine the root cause. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8267 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8268 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8269 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8270 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8271 DTCs that use fault PIDs do not identify the specific concern. The DTC identifies the component(s) or type of component(s) in which the concern exists. The next level, fault PIDs, identifies the specific device and fault condition. Fault PIDs are available for both on-demand (active) and continuous memory (historic or intermittent) DTCs. A scan tool must be used to view the DTCs and their fault PIDs. The table lists those DTCs that are supported by associated fault PIDs. (Figures 1-5) VIEWING FAULT PIDS USING SCAN TOOLS WSM Direction to FLAG DTC/View Fault PIDs The information in viewing fault PIDs in the WSM has evolved over the years as the scan tools have transitioned. Examples of how the WSM may direct you to view fault PIDs are: ^ FLAG DTC XXXXX/Record All Flagged Faults (2001-2006 WS Ms) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8272 ^ View and Record DTC XXXXX Fault PIDs (2007 WSM) ^ DataLogger/View and Record DTC XXXXX Fault Pids (2008 and future WSMs) In each instance the direction is the same (view fault PIDs to identify the specific component and fault condition) but how they are accessed by the scan tools, as well as the scan tool terminology, will vary. FLAG the DTC - View the Fault PIDs For example, the "Flag" DTC feature is specific to NGS/NGS+. When using IDS/PDS it is necessary to view the fault PIDs from DataLogger. Using IDS/PDS NOTE WHEN USING IDS/PDS, MOVE THE CURSOR OVER THE PID OR SELECT THE PID TO DISPLAY ITS DEFINITION AT THE BOTTOM OF THE SCREEN. WHEN USING PDS, HIGHLIGHT OR MOVE THE STYLUS OVER THE PID TO SEE THE PID DEFINITION. 1. Perform a self test of the RCM and/or OCS module to retrieve on-demand and continuous memory DTCs. 2. To view the fault PIDs associated with an on-demand DTC: a. Toolbox b. DataLogger c. Modules d. RCM 3. Monitor all "_OD" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". ^ For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_OD PID reads "FAULT' indicating a front internal crash sensor fault. 4. To view the fault PIDs associated with a continuous memory DTC: a. Toolbox b. DataLogger c. Modules d. RCM 5. Monitor all "_CM" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_CM PID reads "FAULT" indicating a front internal crash sensor fault. IDS/PDS Fault PID Naming Conventions The fault PIDs as displayed on IDS/PDS uses a strategy associating it with the DTC. For example, the fault PIDs 2296_18_OD and 2296_18_CM break down as follows: ^ 2296 - The DTC number minus the "B" (body) or "C" (chassis) designation. ^ 18 - An identifier used to distinguish between each of the fault PIDs associated with the DTC. ^ OD - Identifies the fault PID as an on-demand fault. ^ CM - Identifies the fault PID as a continuous memory (intermittent) fault. NOTE THE DTCS AND FAULT PIDS SUPPORTED BY A VEHICLE WILL VARY DEPENDING ON VEHICLE EQUIPMENT. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8273 Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5) WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Customer Safety Information Air Bag(s) Arming and Disarming: Customer Safety Information WARNING: ^ IF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS BEING SERVICED, THE SYSTEM MUST BE DEACTIVATED AND RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED. ^ THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, TURN THE IGNITION OFF AND DISCONNECT THE BATTERY GROUND CABLE, WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Customer Safety Information > Page 8279 Air Bag(s) Arming and Disarming: Technician Safety Information WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, CAUTIONS, AND NOTES AT THE BEGINNING OF THE DEACTIVATION PROCEDURE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Customer Safety Information > Page 8280 Air Bag(s) Arming and Disarming: Vehicle Damage Warnings CAUTION: ^ Do not handle the passenger air bag module by grabbing the edges of the deployment door. ^ Do not deactivate the side air bag module circuit be removing the side air bag bridge resistor from the side air bag to floor connector. ^ If the side air bag bridge resistor is removed, an open circuit fault will be generated by the Restraints Control Module (RCM). ^ If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Deactivation Procedure Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will This will reduce the risk of injury in the event of an accidental deployment. WARNING: To reduce the risk of personal injury, do not use any memory saver devices. NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood connected. WARNING: To reduce the risk of personal injury, do not use any memory saver devices. NOTE: The air bag warning lamp illuminates when the RGM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8283 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, See: Starting and Charging/Battery 7. Remove the two steering wheel back cover plugs. 8. Remove the driver air bag module retaining bolts. 9. Remove the driver air bag module. 1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8284 10. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector at the top of the steering column. 11. Open the glove compartment door past its stops to access the mounting screws. 12. Remove the two screws. 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Reaching one hand into the glove compartment opening push out on the passenger air bag module and separate it from the instrument panel. Note the wire harness routing for installation. 14. Disconnect the electrical connector and remove the passenger air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8285 15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. Vehicles without seat side air bags 16. CAUTION: Do not deactivate the side air bag module circuit be removing the side air bag bridge resistor from the side air bag to floor connector. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM). If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. Vehicles with seat side air bags and power driver seat 17. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. For additional information, See: Starting and Charging/Battery Vehicles with seat side air bags 18. Move and tilt the front seats to their highest and most forward position. Vehicles with seat side air bags and power driver seat 19. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, See: Starting and Charging/Battery Vehicles with seat side air bags 20. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector. 21. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8286 22. Remove the tie-strap and disconnect the driver seat side air bag electrical connector. 23. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. All vehicles 24. Install the RCM fuse F2.6 (7.5A without rear blower, 15A with rear blower) to the CJB and close the cover. 25. Connect the battery ground cable. For additional See: Starting and Charging/Battery Reactivation Procedure Reactivation All vehicles 1. Turn the ignition switch to OFF. 2. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For additional information, refer to the wiring Diagram Manual. 3. Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, See: Starting and Charging/Battery Vehicles with seat side air bags 4. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8287 5. Connect the driver seat side air bag electrical connector and tie-strap the wire harness. 6. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical connector. 7. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. Vehicles with seat side air bags and power driver seat 8. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. For additional information, See: Starting and Charging/Battery Vehicles with seat side air bags 9. Position the front seats rearward. Vehicles with seat side air bags and power driver seat 10. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, refer to See: Starting and Charging/Battery All vehicles Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8288 11. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. 12. Position the passenger air bag module to the instrument panel (I/P) and connect the electrical connector. 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Position the passenger air bag module into the instrument panel. Route the wire harness as noted in removal. 14. Install the two screws. 15. Close the glove compartment door. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8289 16. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector at the top of the steering column. 17. Position the driver air bag module to the steering wheel. 1. Connect the driver air bag module electrical connector. 2. Position the driver air bag module to the steering wheel. 18. Install the two driver air bag module retaining bolts. 19. Install the two steering wheel back cover plugs. 20. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 21. Turn the ignition switch from OFF to ON. 22. Install the RCM fuse F2.6 (7.5A without rear blower, 15A with rear blower) to the CJB and close the cover. 23. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8290 Connect the battery ground cable. 24. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: -fail to light. -remain lit continuously. -flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. 25. Clear all continuous DTCs from the restraints control module using a scan tool. Seats Removed There are two deactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. WARNING: IF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS BEING SERVICED, THE SYSTEM MUST BE DEACTIVATED AND RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED. THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. NOTE: ^ Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Disconnect the battery ground cable. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the driver air bag module. 4. Attach a Restraint System Diagnostic Tool 418-F088 (105-R0012) to the clockspring side of the driver air bag module connector. 5. Remove the passenger air bag module. 6. Attach a Restraint System Diagnostic Tool 418-F088 (105-R0012) to the vehicle harness side of the passenger air bag connector. 7. If equipped with a front power driver seat, reconnect the battery ground cable. 8. Move and tilt the front seats to their highest and most forward position. 9. If equipped with a front power driver seat, disconnect the battery ground cable. 10. Remove the affected front seat(s). 11. Disconnect the passenger seat side air bag module electrical connector (if necessary) and attach Restraint System Diagnostic Tool 418-133 (40-009) to the vehicle harness side of the passenger seat side air bag module electrical connector. 12. Disconnect the driver seat side air bag module electrical connector (if necessary) and attach Restraint System Diagnostic Tool 418-133 (40-009) to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8291 the vehicle harness side of the driver seat side air bag module electrical connector. 13. Reconnect the battery ground cable. Seats Not Removed There are two deactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. WARNING: IF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS BEING SERVICED, THE SYSTEM MUST BE DEACTIVATED AND RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED. THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. NOTE: ^ Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Disconnect the battery ground cable. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the driver air bag module. 4. Attach a Restraint System Diagnostic Tool 418-F088 (105-R0012) to the clockspring side of the driver air bag module connector. 5. Remove the passenger air bag module. 6. Attach a Restraint System Diagnostic Tool 418-F088 (105-R0012) to the vehicle harness side of the passenger air bag connector. 7. If equipped with seat side air bags and a front power driver seat reconnect the battery ground cable. 8. Move and tilt the front seats to their highest and most forward position. 9. If equipped with seat side air bags and a front power driver seat, disconnect the battery ground cable. 10. If equipped with seat side air bags, disconnect the passenger seat side air bag module electrical connector and attach Restraint System Diagnostic Tool 418-133 (40-009) to the vehicle harness side of the passenger seat side air bag module electrical connector. CAUTION: Vehicles without side air bags, do not deactivate the side air bag module circuit by removing the side air bag bridge resistor from the side air bag floor connector. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM). If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. 11. If equipped with seat side air bags, disconnect the driver seat side air bag module electrical connector and attach Restraint System Diagnostic Tool 418-133 (40-009) to the vehicle harness side of the driver seat side air bag module electrical connector. CAUTION: Vehicles without side air bags, do not deactivate the side air bag module circuit by removing the side air bag bridge resistor from the side air bag floor connector. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8292 If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. 12. Reconnect the battery ground cable. Seats Removed There are two reactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES AND PRETENSIONERS MUST BE RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. 1. Move and tilt the front seats to their highest and most forward position. 2. Disconnect the battery ground cable. 3. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 4. Remove the restraint system diagnostic tool from the driver seat side air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. Remove the restraint system diagnostic tool from the passenger seat side air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 6. Install the affected front seat(s). 7. Connect the driver seat side air bag module electrical connectors. 8. Connect the passenger seat side air bag module electrical connectors. 9. If equipped with a front power driver seat, reconnect the battery ground cable. 10. Move the front seats rearward. 11. If equipped with a front power driver seat, disconnect the battery ground cable. 12. Remove the restraint system diagnostic tool from the passenger air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 13. Install the passenger air bag module. 14. Remove the restraint system diagnostic tool from the clockspring connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 15. Install the driver air bag module. 16. Reconnect the battery ground cable. 17. Prove out the system. Seats Not Removed There are two reactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES AND Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8293 PRETENSIONERS MUST BE RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. 1. If equipped with seat side air bags, move and tilt the front seats to their highest and most forward position. 2. Disconnect the battery ground cable. 3. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 4. If equipped with seat side air bags: 1 Remove the restraint system diagnostic tool from the driver seat side air bag module electrical connector. 2 Remove the restraint system diagnostic tool from the passenger seat side air bag module electrical connector. 3 Connect the driver seat side air bag module electrical connectors. 4 Connect the passenger seat side air bag module electrical connectors. 5 Reconnect the battery ground cable. 6 Move the front seats rearward. 7 Disconnect the battery ground cable. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. Remove the restraint system diagnostic tool from the passenger air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 6. Install the passenger air bag module. 7. Remove the restraint system diagnostic tool from the clockspring connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 8. Install the driver air bag module. 9. Reconnect the battery ground cable. 10. Prove out the system. Procedures For Repair Operations SPECIAL TOOL(S) DEACTIVATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8294 INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the air bag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the seat side air bag (if equipped) and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Remove the retaining screws and position the hood release handle out of the way. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8295 3. Remove the lower steering column opening finish panel. 1 Remove the two retaining screws from the lower steering column opening finish panel. 2 Pull out to release the retaining clips and remove the lower steering column opening finish panel. 4. Remove the bolts and the lower steering column opening finish panel reinforcement. 5. Disconnect the clockspring electrical connector at the base of the steering column. 6. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8296 7. Open the glove compartment door past its stops to access the mounting screws. 8. Remove the two screws. 9. Reaching one hand into the glove compartment opening, push out on the passenger air bag module and separate it from the instrument panel. Note the wire harness routing for installation. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. 10. Disconnect the electrical connector and remove the passenger air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8297 11. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. Vehicles without seat side air bags 12. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the Restraints Control Module (RCM). If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. CAUTION: Do not deactivate the side air bag module circuit be removing the side air bag bridge resistor from the side air bag to floor connector. Vehicles with seat side air bags and power driver seat 13. Connect the battery ground cable. Vehicles with seat side air bags 14. Move and tilt the front seats to their highest and most forward position. Vehicles with seat side air bags and power driver seat 15. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Vehicles with seat side air bags 16. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8298 17. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. 18. Remove the tie-strap and disconnect the driver seat side air bag electrical connector. 19. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. All vehicles 20. Connect the battery ground cable. 21. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). See: Prove Out Procedure 22. Disconnect the battery ground cable and wait at least one minute. REACTIVATION WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, CAUTIONS, AND NOTES AT THE BEGINNING OF THE DEACTIVATION PROCEDURE. Vehicles with seat side air bags Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8299 1. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical connector. NOTE: Make sure the battery ground cable is still disconnected before proceeding with the reactivation portion of this procedure. 2. Connect the driver seat side air bag electrical connector and tie-strap the wire harness. 3. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical connector. 4. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. Vehicles with seat side air bags and power driver seat 5. Connect the battery ground cable. Vehicles with seat side air bags 6. Position the front seats rearward. Vehicles with seat side air bags and power driver seat Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8300 7. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). All vehicles 8. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. 9. Position the passenger air bag module to the Instrument Panel (I/P) and connect the electrical connector. 10. Position the passenger air bag module into the instrument panel. Route the wire harness as noted in removal. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8301 11. In stall the two screws. 12. Close the glove compartment door. 13. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector at the base of the steering column. 14. Connect the clockspring electrical connector at the base of the steering column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8302 15. Position the lower steering column opening finish panel reinforcement and install the bolts. 16. Install the lower steering column opening finish panel. 1 Position the lower steering column opening finish panel to the I/P and push in at the top to seat the retaining clips. 2 Install the screws. 17. Position the hood release handle and install the screws. 18. Connect the battery ground cable. 19. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Prove Out Procedure WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 20. Check the active restraint system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8303 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag modules connected? 3. Is the Restraints Control Module (RCM) connected? 4. Is the vehicle battery connected? Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8304 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure Turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator with the air bag modules or restraint system diagnostic tools installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag Supplemental Restraint System (SRS) fault is present, the air bag indicator will either: ^ fail to light. ^ remain lit continuously. ^ flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the RUN position. This is the time required for the Restraints Control Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Page 8305 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Child Restraint > Child Seat Tether Attachment > Component Information > Description and Operation Child Seat Tether Attachment: Description and Operation Some manufacturers make child safety seats that include a tether strap that goes over the back of the vehicle seat and attaches to an anchoring point. Other manufacturers offer the tether strap as an accessory. Contact the manufacturer of the child safety seat for information about ordering a tether strap. The child safety seat tether strap anchors (3) are located on the back panel sheet metal under a cover marked with the tether symbol. If the tether strap anchors were in use during a collision the back panel sheet metal must be reworked to its original condition and structural integrity. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Child Restraint > Child Seat Tether Attachment > Component Information > Description and Operation > Page 8310 Child Seat Tether Attachment: Service and Repair REMOVAL 1. Position the carpet back, in the rear storage area, to access the child safety seat tether anchors (cargo tie-downs). 2. Remove the child safety seat tether anchor (cargo tie-down). 1 Remove the bolts. 2 Remove the child safety seat tether anchor (cargo tie-down). INSTALLATION 1. Install the child safety seat tether anchor (cargo tie-down). 1 Position the child safety seat tether anchor (cargo tie-down). 2 Install the bolts. 3 Apply Ultra Silicone Sealant F7TZ-19554-AA or equivalent. NOTE: Rework the sheet metal to its original condition and structural integrity. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Child Restraint > Child Seat Tether Attachment > Component Information > Description and Operation > Page 8311 2. Position the carpet back in the rear storage area. ^ The child safety seat tether anchors (cargo tie-downs) must be positioned through the openings in the carpet, allowing accessibility. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt > Component Information > Technical Service Bulletins > Restraints - Seat Belt Stop Button Service Seat Belt: Technical Service Bulletins Restraints - Seat Belt Stop Button Service TSB 05-3-10 02/21/05 SAFETY BELT WEB STOP BUTTON SERVICE FORD: 2000-2004 Mustang 2000-2005 Crown Victoria, Focus, Taurus 1999-2005 F-Super Duty 2000-2003 Windstar 2000-2005 Excursion, F-150, Ranger 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2002-2005 Explorer 2003-2004 Expedition 2004-2005 Freestar 2005 Escape Hybrid LINCOLN: 2000-2005 LS, Town Car 2003-2004 Navigator 2003-2005 Aviator MERCURY: 2000-2005 Sable 2001-2005 Mariner 2002-2005 Mountaineer 2004-2005 Monterey ISSUE To service a safety belt web stop button (the button that keeps the belt tongue from sliding down when not in use), a service kit is now available. ACTION Install the safety belt button kit, DO NOT replace the entire safety belt assembly. Follow the Service Procedure in the Instruction Sheet that comes with the kit. Refer to Section 501-20A of the appropriate model year Workshop Manual for additional information if needed. NOTE ONE KIT WILL REPAIR ONE SEAT BELT BUTTON. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 70611B09 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt > Component Information > Service Precautions > Customer Safety Information Seat Belt: Customer Safety Information WARNING: AFTER ANY VEHICLE COLLISION, THE SAFETY BELT SYSTEM AT ALL OUTBOARD SEATING POSITIONS (EXCEPT DRIVER, WHICH HAS NO "AUTOMATIC LOCKING RETRACTOR" FEATURE) MUST BE CHECKED BY A QUALIFIED TECHNICIAN TO VERIFY THAT THE "AUTOMATIC LOCKING RETRACTOR" FEATURE FOR CHILD SEATS IS STILL FUNCTIONING PROPERLY, IN ADDITION TO OTHER CHECKS FOR PROPER SAFETY BELT SYSTEM FUNCTION. A BELT AND RETRACTOR ASSEMBLY MUST BE REPLACED IF THE SAFETY BELT ASSEMBLY'S "AUTOMATIC LOCKING RETRACTOR" FEATURE OR ANY OTHER SAFETY BELT FUNCTION IS NOT OPERATING PROPERLY WHEN CHECKED ACCORDING TO THE PROCEDURES IN THE WORKSHOP MANUAL. FAILURE TO REPLACE THE BELT AND RETRACTOR ASSEMBLY COULD INCREASE THE RISK OF INJURY IN COLLISIONS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt > Component Information > Service Precautions > Customer Safety Information > Page 8318 Seat Belt: Technician Safety Information WARNING: ^ ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. ^ AFTER ANY VEHICLE COLLISION, THE SAFETY BELT SYSTEM AT ALL OUTBOARD SEATING POSITIONS (EXCEPT DRIVER, WHICH HAS NO "AUTOMATIC LOCKING RETRACTOR" FEATURE) MUST BE CHECKED BY A QUALIFIED TECHNICIAN TO VERIFY THAT THE "AUTOMATIC LOCKING RETRACTOR" FEATURE FOR CHILD SEATS IS STILL FUNCTIONING PROPERLY, IN ADDITION TO OTHER CHECKS FOR PROPER SAFETY BELT SYSTEM FUNCTION. A BELT AND RETRACTOR ASSEMBLY MUST BE REPLACED IF THE SAFETY BELT ASSEMBLY'S "AUTOMATIC LOCKING RETRACTOR" FEATURE, OR ANY OTHER SAFETY BELT FUNCTION, IS NOT OPERATING PROPERLY WHEN CHECKED ACCORDING TO THE PROCEDURES IN THE WORKSHOP MANUAL. FAILURE TO REPLACE THE BELT AND RETRACTOR ASSEMBLY COULD INCREASE THE RISK OF INJURY IN COLLISIONS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt > Component Information > Service Precautions > Page 8319 Seat Belt: Description and Operation NOTE: When installing a new dual locking mode retractor, the retractor should be checked to make sure it is not in the Automatic Locking Retractor (ALR) mode after installation in the stowed position. All outboard continuous-loop, three-point retractor systems, except the driver position, are equipped with the dual locking mode system. The Emergency Locking Retractor (ELR) mode will allow the occupant freedom of movement, locking tight only on hard braking, hard cornering, or an impact of approximately 8 km/h (5 mph). The ELR mode helps to reduce the forward movement of the driver and passengers. The ELR mode is continuously in operation at all seating positions. The ALR portion of this system does not allow the occupant freedom of movement. The ALR mode is used when locking a child seat in an outboard seating position or when a tight belt fit is desired. The ALR mode is disengaged when the webbing is free to move in or out of the retractor. The ALR mode is automatically engaged when the webbing is fully extracted from the retractor and then allowed to retract. As the webbing is retracted back onto the spool, an audible clicking sound is made, indicating that the retractor is in ALR mode. The ALR mode is automatically disengaged when most of the webbing is retracted back onto the spool. WARNING: AFTER ANY VEHICLE COLLISION, THE SAFETY BELT SYSTEM AT ALL OUTBOARD SEATING POSITIONS (EXCEPT DRIVER, WHICH HAS NO "AUTOMATIC LOCKING RETRACTOR" FEATURE) MUST BE CHECKED BY A QUALIFIED TECHNICIAN TO VERIFY THAT THE "AUTOMATIC LOCKING RETRACTOR" FEATURE FOR CHILD SEATS IS STILL FUNCTIONING PROPERLY, IN ADDITION TO OTHER CHECKS FOR PROPER SAFETY BELT SYSTEM FUNCTION. A BELT AND RETRACTOR ASSEMBLY MUST BE REPLACED IF THE SAFETY BELT ASSEMBLY'S "AUTOMATIC LOCKING RETRACTOR" FEATURE OR ANY OTHER SAFETY BELT FUNCTION IS NOT OPERATING PROPERLY WHEN CHECKED ACCORDING TO THE PROCEDURES IN THE WORKSHOP MANUAL. FAILURE TO REPLACE THE BELT AND RETRACTOR ASSEMBLY COULD INCREASE THE RISK OF INJURY IN COLLISIONS. This vehicle has a safety belt system with an energy management feature at the front seating positions to help further reduce the risk of injury in the event of a head-on collision. This safety belt system has a retractor assembly that is designed to pay out webbing in a controlled manner. This feature is designed to help reduce the belt force acting on an occupant's chest. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt > Component Information > Service Precautions > Page 8320 Seat Belt: Testing and Inspection Automatic Locking Retractor - Evaluation of Lockability and Release WARNING: AFTER ANY VEHICLE COLLISION, THE SAFETY BELT SYSTEM AT ALL OUTBOARD SEATING POSITIONS (EXCEPT DRIVER, WHICH HAS NO "AUTOMATIC LOCKING RETRACTOR" FEATURE) MUST BE CHECKED BY A QUALIFIED TECHNICIAN TO VERIFY THAT THE "AUTOMATIC LOCKING RETRACTOR" FEATURE FOR CHILD SEATS IS STILL FUNCTIONING PROPERLY, IN ADDITION TO OTHER CHECKS FOR PROPER SAFETY BELT SYSTEM FUNCTION. A BELT AND RETRACTOR ASSEMBLY MUST BE REPLACED IF THE SAFETY BELT ASSEMBLY'S "AUTOMATIC LOCKING RETRACTOR" FEATURE, OR ANY OTHER SAFETY BELT FUNCTION, IS NOT OPERATING PROPERLY WHEN CHECKED ACCORDING TO THE PROCEDURES IN THE WORKSHOP MANUAL. FAILURE TO REPLACE THE BELT AND RETRACTOR ASSEMBLY COULD INCREASE THE RISK OF INJURY IN COLLISIONS. 1. Extend the safety belt to latch the tongue into the buckle across an empty seat without slack in the safety belt, with the seat in the full down and rearmost position, seat back in an upright position, and if applicable, the D-ring adjusted in the full down position. 2. Pull the shoulder belt to full extension to engage the retractor's Automatic Locking Retractor (ALR) feature. Then allow the belt to retract freely in the ALR mode, and the retractor force set the correct belt tightness. 3. Pull on the shoulder belt to check that the belt has remained in the ALR mode. If the belt is not locked, install a new belt and retractor assembly. The safety belt should remain locked in the ALR mode across an empty seat. 4. To verify that the safety belt still automatically disengages from the ALR mode correctly, with the D-ring adjusted to the full up position, if applicable, unlatch the safety belt tongue from the buckle and allow the safety belt to retract to its stowed position. Pull on the shoulder belt to verify that the retractor assembly has converted automatically out of the ALR mode. If the belt remains locked in the stowed position, a new belt and retractor assembly must be installed. The safety belt should extract freely. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt > Component Information > Service and Repair > Front Safety Belt Retractor Seat Belt: Service and Repair Front Safety Belt Retractor Two-Door Safety Belt Bolt Bit SPECIAL TOOL(S) REMOVAL WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. NOTE: Driver side shown, passenger side similar. 1. Remove the rear quarter trim panel. 2. Remove the safety belt web guide. 1 Remove the bolt. 2 Remove the safety belt web guide from the B-pillar. 3. Remove the front safety belt retractor. 1 Using the special tool, remove the bolt. 2 Remove the front safety belt retractor. INSTALLATION Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt > Component Information > Service and Repair > Front Safety Belt Retractor > Page 8323 1. Install the front safety belt retractor. 1 Position the front safety belt retractor to the B-pillar. 2 Using the special tool, install the bolt. NOTE: Make sure to tighten nuts and bolts to specification. 2. Install the safety belt web guide. 1 Position the safety belt web guide to the B-pillar. 2 Install the bolt. NOTE: ^ Make sure the safety belt webbing is not twisted prior to installation. ^ Make sure to tighten nuts and bolts to specification. 3. Install the rear quarter trim panel. NOTE: Make sure the safety belt webbing is not twisted prior to installation. 4. Check the active restraint system for correct operation. Four-Door Safety Belt Bolt Bit SPECIAL TOOL(S) REMOVAL WARNING: ALL SAFETY BELT ASSEMBLIES. INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt > Component Information > Service and Repair > Front Safety Belt Retractor > Page 8324 SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. NOTE: Passenger side shown, driver side similar. 1. Remove the B-pillar trim panel. 2. Remove the front safety belt retractor. 1 Remove the bolt. 2 Using the special tool, remove the bolt. 3 Remove the front safety belt retractor. INSTALLATION 1. Install the front safety belt retractor. 1 Position the front safety belt retractor to the B-pillar. 2 Using the special tool, install the front safety belt retractor bolt. 3 Install the bolt, being careful not to overtighten. NOTE: Make sure to tighten nuts and bolts to specification. 2. Install the B-pillar trim panel. 3. Check the active restraint system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt > Component Information > Service and Repair > Front Safety Belt Retractor > Page 8325 Seat Belt: Service and Repair Rear Safety Belt Retractor Four-Door Safety Belt Bolt Bit SPECIAL TOOL(S) REMOVAL WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. NOTE: Passenger side shown, driver side similar. 1. Remove the C-pillar trim panel. 2. Remove the rear safety belt retractor. 1 Using the special tool, remove the bolt. 2 Remove the safety belt retractor. INSTALLATION 1. Install the rear safety belt retractor. 1 Position the safety belt retractor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt > Component Information > Service and Repair > Front Safety Belt Retractor > Page 8326 2 Using the special tool, install the bolt. NOTE: Make sure to tighten nuts and bolts to specification. 2. Install the C-pillar trim panel. NOTE: Make sure the safety belt webbing is not twisted prior to installation. 3. Check the active restraint system for correct operation. Two-Door Safety Belt Bolt Bit SPECIAL TOOL(S) REMOVAL WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. NOTE: Driver side shown, passenger side similar. 1. Remove the rear quarter trim panel. 2. Remove the rear safety belt retractor. 1 Using the special tool, remove the bolt. 2 Remove the rear safety belt retractor. INSTALLATION Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt > Component Information > Service and Repair > Front Safety Belt Retractor > Page 8327 1. Install the rear safety belt retractor. 1 Position the rear safety belt retractor to the B-pillar. 2 Using the special tool, install the bolt. NOTE: Make sure to tighten nuts and bolts to specification. 2. Install the rear quarter trim panel. NOTE: Make sure the safety belt webbing is not twisted prior to installation. 3. Check the active restraint system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt > Component Information > Service and Repair > Front Safety Belt Retractor > Page 8328 Seat Belt: Service and Repair Rear Center Safety Belt Retractor - Four-Door Safety Belt Bolt Bit SPECIAL TOOL(S) REMOVAL WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED) CHILD SAFETY SEAT TETHER ATTACHMENTS AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. 1. Fold the rear seat down to load floor position. 2. Remove the rear safety belt buckle and retractor assembly. 1 Using the special tool, remove the bolt. 2 Remove the rear safety belt buckle and retractor assembly. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Make sure the safety belt webbing is not twisted prior to installation. 2. Check the restraint system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt > Component Information > Service and Repair > Page 8329 Seat Belt Bolt Bit Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Buckle > Component Information > Service Precautions Seat Belt Buckle: Service Precautions WARNING: ^ ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED) CHILD SAFETY SEAT TETHER ATTACHMENTS AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE AND IN THE FRONT SEAT REMOVAL AND INSTALLATION PROCEDURE. Refer to Air Bag(s) Arming and Disarming. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Buckle > Component Information > Service and Repair > Front Seat Belt Buckle: Service and Repair Front With Seat Side Air Bags Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. ^ ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. NOTE: Driver side is shown, passenger side is similar. 1. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Deactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Buckle > Component Information > Service and Repair > Front > Page 8335 WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. Refer to Air Bag(s) Arming and Disarming. 3. Remove the front driver or passenger seat from the vehicle. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE FRONT SEAT REMOVAL AND INSTALLATION PROCEDURE. 4. Remove the safety belt buckle support assembly. 1 Remove the nut. 2 Remove the bolt. 3 Remove the safety belt buckle support assembly. 5. Remove the safety belt buckle. 1 Clamp the safety belt buckle support assembly in a suitable vise. 2 Using the special tool, remove the safety belt buckle bolt. 3 Remove the safety belt buckle. NOTE: Clamp the safety belt buckle support assembly collar in a vise along the break line only. INSTALLATION 1. Install the safety belt buckle onto the safety belt buckle support assembly. 1 Position the safety belt buckle onto the safety belt buckle support assembly. 2 Using the special tool, install the safety belt buckle bolt. 3 Remove the safety belt buckle support assembly from the vise. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Buckle > Component Information > Service and Repair > Front > Page 8336 2. Install the safety belt buckle support assembly onto the seat. 1 Position the safety belt buckle support assembly to the seat. 2 Install the nut and bolt. 3. Install the front driver or passenger seat into the vehicle. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE FRONT SEAT REMOVAL AND INSTALLATION PROCEDURE. 4. Reactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. Refer to Air Bag(s) Arming and Disarming. 5. With all the diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 6. Check the active restraint system for correct operation. Without Seat Side Air Bags Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Buckle > Component Information > Service and Repair > Front > Page 8337 Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. ^ ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. NOTE: Driver side is shown, passenger side is similar. 1. Remove the front driver or passenger seat from the vehicle. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE FRONT SEAT REMOVAL AND INSTALLATION PROCEDURE. 2. Remove the safety belt buckle support assembly. 1 Remove the nut. 2 Remove the bolt. 3 Remove the safety belt buckle support assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Buckle > Component Information > Service and Repair > Front > Page 8338 3. Remove the safety belt buckle. 1 Clamp the safety belt buckle support assembly in a suitable vise. 2 Using the special tool, remove the safety belt buckle bolt. 3 Remove the safety belt buckle. NOTE: Clamp the safety belt buckle support assembly collar in a vise along the break line only. INSTALLATION 1. Install the safety belt buckle onto the safety belt buckle support assembly. 1 Position the safety belt buckle onto the safety belt buckle support assembly. 2 Using the special tool, install the safety belt buckle bolt. 3 Remove the safety belt buckle support assembly from the vise. 2. Install the safety belt buckle support assembly onto the seat. 1 Position the safety belt buckle support assembly to the seat. 2 Install the nut and bolt. 3. Check the active restraint system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Buckle > Component Information > Service and Repair > Front > Page 8339 Seat Belt Buckle: Service and Repair Rear Center and Left Side, Four-Door REMOVAL WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED) CHILD SAFETY SEAT TETHER ATTACHMENTS AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. 1. Remove the rear seats. 2. Remove the rear safety belt buckle assembly. 1 Remove the nuts. 2 Remove the rear safety belt buckle assembly. INSTALLATION 1. To install, reverse the removal procedure. ^ Check the restraint system for correct operation. Right Side, Four-Door REMOVAL WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. 1. Fold the rear seat down to load floor position. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Buckle > Component Information > Service and Repair > Front > Page 8340 2. Remove the rear safety belt buckle and retractor assembly. 1 Using the special tool, remove the bolt. 2 Remove the rear safety belt buckle and retractor assembly. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Make sure the safety belt webbing is not twisted prior to installation. 2. Check the active restraint system for correct operation. Two-Door REMOVAL WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED) CHILD SAFETY SEAT TETHER ATTACHMENTS AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. 1. Remove the rear seats. 2. Remove the rear safety belt buckles. 1 Remove the nuts. 2 Remove the rear safety belt buckles. INSTALLATION Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Buckle > Component Information > Service and Repair > Front > Page 8341 1. To install, reverse the removal procedure. ^ Check the restraint system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Buckle > Component Information > Service and Repair > Page 8342 Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Buckle Switch > Component Information > Diagrams Connector View C323 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs Seat Belt Control Module: Technical Service Bulletins Restraints - Control Module DTCs & Associated Fault PIDs TSB 07-12-3 06/25/07 RCM FAULT REPORTING USING DTCS AND BIT-MAPPED PARAMETER IDENTIFIERS (PIDS) - SERVICE TIPS FORD: 2001-2007 Crown Victoria 2002-2007 Taurus 2004-2007 Focus 2005-2007 Five Hundred, Freestyle, Mustang 2006-2007 Fusion 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac 2002-2003 Windstar 2002-2007 Explorer 2003-2007 Expedition 2004-2007 F-150, Freestar 2005-2007 Escape Hybrid, Escape 2007 E-Series LINCOLN: 2001-2007 Town Car 2003-2006 Lincoln LS 2006 Zephyr 2007 MKZ 2003-2005 Aviator 2003-2007 Navigator 2006-2007 Mark LT MERCURY: 2001-2007 Grand Marquis 2002-2005 Sable 2005-2007 Montego 2006-2007 Milan 2002-2007 Mountaineer 2004-2007 Monterey 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 07-7-8 to update the vehicle application. ISSUE Various 2001-2007 vehicles are equipped with a restraints control module (RCM) that report diagnostic trouble codes (DTCs) which provide general fault information. These DTCs require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific fault. Most 2001-2006 Workshop Manuals (WSM) were written using New Generation STAR Tester (NGS) terminology and navigation which does not translate well when using Integrated Diagnostic System (IDS), Portable Diagnostic Software (PDS) or Worldwide Diagnostic System (WDS). ACTION Refer to the Service Tips to assist with navigation of both the WSM and the scan tool being used. SERVICE TIPS DTCs And Associated Fault PIDs Description Many of the continuous memory and on-demand DTCs that can be present in the RCM provide general fault information and require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific concern. DTCs that use fault PIDs are conceptually different from conventional DTCs. Conventional DTCs identify a specific concern for a given component and point to a particular diagnostic path. In the diagnostic path, PIDs are sometimes used to determine the root cause. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8350 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8351 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8352 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8353 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8354 DTCs that use fault PIDs do not identify the specific concern. The DTC identifies the component(s) or type of component(s) in which the concern exists. The next level, fault PIDs, identifies the specific device and fault condition. Fault PIDs are available for both on-demand (active) and continuous memory (historic or intermittent) DTCs. A scan tool must be used to view the DTCs and their fault PIDs. The table lists those DTCs that are supported by associated fault PIDs. (Figures 1-5) VIEWING FAULT PIDS USING SCAN TOOLS WSM Direction to FLAG DTC/View Fault PIDs The information in viewing fault PIDs in the WSM has evolved over the years as the scan tools have transitioned. Examples of how the WSM may direct you to view fault PIDs are: ^ FLAG DTC XXXXX/Record All Flagged Faults (2001-2006 WS Ms) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8355 ^ View and Record DTC XXXXX Fault PIDs (2007 WSM) ^ DataLogger/View and Record DTC XXXXX Fault Pids (2008 and future WSMs) In each instance the direction is the same (view fault PIDs to identify the specific component and fault condition) but how they are accessed by the scan tools, as well as the scan tool terminology, will vary. FLAG the DTC - View the Fault PIDs For example, the "Flag" DTC feature is specific to NGS/NGS+. When using IDS/PDS it is necessary to view the fault PIDs from DataLogger. Using IDS/PDS NOTE WHEN USING IDS/PDS, MOVE THE CURSOR OVER THE PID OR SELECT THE PID TO DISPLAY ITS DEFINITION AT THE BOTTOM OF THE SCREEN. WHEN USING PDS, HIGHLIGHT OR MOVE THE STYLUS OVER THE PID TO SEE THE PID DEFINITION. 1. Perform a self test of the RCM and/or OCS module to retrieve on-demand and continuous memory DTCs. 2. To view the fault PIDs associated with an on-demand DTC: a. Toolbox b. DataLogger c. Modules d. RCM 3. Monitor all "_OD" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". ^ For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_OD PID reads "FAULT' indicating a front internal crash sensor fault. 4. To view the fault PIDs associated with a continuous memory DTC: a. Toolbox b. DataLogger c. Modules d. RCM 5. Monitor all "_CM" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_CM PID reads "FAULT" indicating a front internal crash sensor fault. IDS/PDS Fault PID Naming Conventions The fault PIDs as displayed on IDS/PDS uses a strategy associating it with the DTC. For example, the fault PIDs 2296_18_OD and 2296_18_CM break down as follows: ^ 2296 - The DTC number minus the "B" (body) or "C" (chassis) designation. ^ 18 - An identifier used to distinguish between each of the fault PIDs associated with the DTC. ^ OD - Identifies the fault PID as an on-demand fault. ^ CM - Identifies the fault PID as a continuous memory (intermittent) fault. NOTE THE DTCS AND FAULT PIDS SUPPORTED BY A VEHICLE WILL VARY DEPENDING ON VEHICLE EQUIPMENT. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 8356 Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5) WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Extension > Component Information > Description and Operation Seat Belt Extension: Description and Operation In certain cases, the safety belt may be too short even when it is fully extended. About 20 cm (8 in) can be added to the belt length by using a safety belt extension. Safety belt extensions are available at no cost from any Ford or Lincoln-Mercury dealer parts department. Safety belt extensions are only available with black webbing. There are two extension assemblies available, one for the front seating positions and one for the rear seating positions, and they are not interchangeable. Use only extensions manufactured by the same supplier of the safety belt. Manufacturer identification is located at the end of the webbing on the label. Also, use the safety belt extension only if the safety belt is too short for the occupant when fully extended. Do not use an extension to change the fit of the shoulder belt across the torso. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Height Adjuster > Component Information > Service and Repair > Removal and Installation Seat Belt Height Adjuster: Service and Repair Removal and Installation Safety Belt Bolt Bit SPECIAL TOOL(S) REMOVAL 1. Remove the B-pillar trim panel. 2. Remove the height adjuster cover. 3. Remove the shoulder safety belt height adjuster. 1 Using the special tool, remove the two bolts. 2 Remove the shoulder safety belt height adjuster. INSTALLATION 1. To install, reverse the removal procedure. 2. Check the restraint system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Height Adjuster > Component Information > Service and Repair > Removal and Installation > Page 8364 Seat Belt Height Adjuster: Service and Repair General Procedures D-Ring Installation Kit SPECIAL TOOL(S) 1. Remove the B-pillar trim panel. 2. Use the half-inch drill with integral stop provided in D-Ring Installation Kit to drill out the damaged threads in the upper pillar structure. 3. Apply a suitable lubricant to the M14 x 1.5 tap with integral stop provided in D-Ring Installation Kit and tap new threads. NOTE: After each rotation, back off tap slightly to remove new cuttings and be sure to blow out any chips before proceeding. 4. Use a threaded insert (N807170-S190) provided in the D-Ring Installation Kit and screw it into the retapped bole until it is slightly below the surface. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Height Adjuster > Component Information > Service and Repair > Removal and Installation > Page 8365 5. Use a hammer to lightly tap the installation tool provided in the D-Ring Installation Kit several times to seat the insert keys. NOTE: If the two bolts on the height adjuster are not stripped, install the height adjuster. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Height Adjuster > Component Information > Service and Repair > Page 8366 Seat Belt Height Adjuster: Tools and Equipment D-Ring Installation Kit Seat Belt Bolt Bit Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Reminder Lamp > Component Information > Description and Operation Seat Belt Reminder Lamp: Description and Operation Safety Belt Warning Indicator and Chime The warning indicator and chime are reminders to fasten the safety belt. The following conditions will take place: If the safety belt is not buckled before the ignition is turned to the ON position, the chime will turn on for four to eight seconds and the indicator will come on for one to two minutes. - If the safety belt is buckled while the indicator is on and the chime is sounding, both the indicator and chime will turn off. - If the safety belt is buckled before the ignition is turned to the ON position, neither the indicator nor the chime will turn on. Belt Minder (if equipped) The Belt Minder feature is a supplemental warning to the safety belt warning function. This feature provides additional reminders to the driver that the driver's safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning lamp in the instrument cluster. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Retractor: > 05-16-11 > Aug > 05 > Restraints - Seat Belts Slow to Retract Seat Belt Retractor: Customer Interest Restraints - Seat Belts Slow to Retract TSB 05-16-11 08/22/05 SAFETY BELT RETRACTION SPEED FORD: 2000-2003 Mustang 2000-2006 Crown Victoria, Taurus 2000-2003 Explorer Sport, Windstar 2000-2005 Excursion, Explorer 2000-2006 E-Series, Expedition, F-150, F-Super Duty, Ranger 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape Hybrid 2004-2006 F-650, F-750 LINCOLN: 2000-2002 Continental 2000-2006 LS, Town Car, Navigator 2003-2005 Aviator MERCURY: 2000-2005 Sable 2000-2006 Grand Marquis 2000-2005 Mountaineer 2004-2006 Monterey 2005-2006 Mariner This article supersedes TSB 04-24-21 to update the vehicle model years. ISSUE A service kit is now available to improve safety belt retraction speed. ACTION See the part application chart and select the appropriate kit. Follow the Instruction Sheet included in the kit. Refer to Workshop Manual Section 501-20A for additional information. NOTE TEFLON TAPE SHOULD ONLY BE USED ON THE FRONT ROW SEATS FOR VEHICLES LISTED IN THIS TSB, WITH THE EXCEPTION OF THE AVIATOR, EXPLORER 4DR AND THE MOUNTAINEER. TEFLON TAPE CAN ALSO BE USED ON SECOND ROW SEATS FOR THESE THREE VEHICLES. NOTE FOR MUSTANG, AVIATOR, EXPLORER 4DR AND MOUNTAINEER, REFER TO THE FOLLOWING BUILD DATE INFORMATION BEFORE PERFORMING THIS TSB. TEFLON TAPE HAS ALREADY BEEN INSTALLED DURING PRODUCTION ON SOME OF THESE VEHICLES. ^ MUSTANG: Only install on vehicles built through 6/15/2003. Teflon tape was already installed on vehicles built on/after 6/16/2003. ^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (FRONT ROW SEATS): Only install on vehicles built through 6/24/2004. Teflon tape was already installed on vehicles built on/after 6/25/2004. ^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (SECOND ROW SEATS): Only install on vehicles built through 10/21/2004. Teflon tape was already installed on vehicles built on/after 10/22/2004. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Retractor: > 05-16-11 > Aug > 05 > Restraints - Seat Belts Slow to Retract > Page 8378 Parts Block NOTE THE LABOR OPERATIONS WITHIN THIS TSB CAN BE CLAIMED IN COMBINATION AS NEEDED TO COVER THE REQUIRED REPAIRS. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051611A Install Teflon Tape B 0.8 Hr. Pillars Both Sides (Includes Time To Remove And Install Trim Panels If Necessary) 051611B Install Teflon Tape C 1.1 Hrs. Pillars Both Sides (Includes Time To Remove And Install Trim Panels And Seats If Necessary) DEALER CODING CONDITION BASIC PART NO. CODE 70611B08 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 05-16-11 > Aug > 05 > Restraints - Seat Belts Slow to Retract Seat Belt Retractor: All Technical Service Bulletins Restraints - Seat Belts Slow to Retract TSB 05-16-11 08/22/05 SAFETY BELT RETRACTION SPEED FORD: 2000-2003 Mustang 2000-2006 Crown Victoria, Taurus 2000-2003 Explorer Sport, Windstar 2000-2005 Excursion, Explorer 2000-2006 E-Series, Expedition, F-150, F-Super Duty, Ranger 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape Hybrid 2004-2006 F-650, F-750 LINCOLN: 2000-2002 Continental 2000-2006 LS, Town Car, Navigator 2003-2005 Aviator MERCURY: 2000-2005 Sable 2000-2006 Grand Marquis 2000-2005 Mountaineer 2004-2006 Monterey 2005-2006 Mariner This article supersedes TSB 04-24-21 to update the vehicle model years. ISSUE A service kit is now available to improve safety belt retraction speed. ACTION See the part application chart and select the appropriate kit. Follow the Instruction Sheet included in the kit. Refer to Workshop Manual Section 501-20A for additional information. NOTE TEFLON TAPE SHOULD ONLY BE USED ON THE FRONT ROW SEATS FOR VEHICLES LISTED IN THIS TSB, WITH THE EXCEPTION OF THE AVIATOR, EXPLORER 4DR AND THE MOUNTAINEER. TEFLON TAPE CAN ALSO BE USED ON SECOND ROW SEATS FOR THESE THREE VEHICLES. NOTE FOR MUSTANG, AVIATOR, EXPLORER 4DR AND MOUNTAINEER, REFER TO THE FOLLOWING BUILD DATE INFORMATION BEFORE PERFORMING THIS TSB. TEFLON TAPE HAS ALREADY BEEN INSTALLED DURING PRODUCTION ON SOME OF THESE VEHICLES. ^ MUSTANG: Only install on vehicles built through 6/15/2003. Teflon tape was already installed on vehicles built on/after 6/16/2003. ^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (FRONT ROW SEATS): Only install on vehicles built through 6/24/2004. Teflon tape was already installed on vehicles built on/after 6/25/2004. ^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (SECOND ROW SEATS): Only install on vehicles built through 10/21/2004. Teflon tape was already installed on vehicles built on/after 10/22/2004. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 05-16-11 > Aug > 05 > Restraints - Seat Belts Slow to Retract > Page 8384 Parts Block NOTE THE LABOR OPERATIONS WITHIN THIS TSB CAN BE CLAIMED IN COMBINATION AS NEEDED TO COVER THE REQUIRED REPAIRS. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051611A Install Teflon Tape B 0.8 Hr. Pillars Both Sides (Includes Time To Remove And Install Trim Panels If Necessary) 051611B Install Teflon Tape C 1.1 Hrs. Pillars Both Sides (Includes Time To Remove And Install Trim Panels And Seats If Necessary) DEALER CODING CONDITION BASIC PART NO. CODE 70611B08 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Service Precautions > Customer Safety Information Seat Belt Retractor: Customer Safety Information WARNING: AFTER ANY VEHICLE COLLISION, THE SAFETY BELT SYSTEM AT ALL OUTBOARD SEATING POSITIONS (EXCEPT DRIVER, WHICH HAS NO "AUTOMATIC LOCKING RETRACTOR" FEATURE) MUST BE CHECKED BY A QUALIFIED TECHNICIAN TO VERIFY THAT THE "AUTOMATIC LOCKING RETRACTOR" FEATURE FOR CHILD SEATS IS STILL FUNCTIONING PROPERLY, IN ADDITION TO OTHER CHECKS FOR PROPER SAFETY BELT SYSTEM FUNCTION. A BELT AND RETRACTOR ASSEMBLY MUST BE REPLACED IF THE SAFETY BELT ASSEMBLY'S "AUTOMATIC LOCKING RETRACTOR" FEATURE OR ANY OTHER SAFETY BELT FUNCTION IS NOT OPERATING PROPERLY WHEN CHECKED ACCORDING TO THE PROCEDURES IN THE WORKSHOP MANUAL. FAILURE TO REPLACE THE BELT AND RETRACTOR ASSEMBLY COULD INCREASE THE RISK OF INJURY IN COLLISIONS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Service Precautions > Customer Safety Information > Page 8387 Seat Belt Retractor: Technician Safety Information WARNING: ^ ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. ^ AFTER ANY VEHICLE COLLISION, THE SAFETY BELT SYSTEM AT ALL OUTBOARD SEATING POSITIONS (EXCEPT DRIVER, WHICH HAS NO "AUTOMATIC LOCKING RETRACTOR" FEATURE) MUST BE CHECKED BY A QUALIFIED TECHNICIAN TO VERIFY THAT THE "AUTOMATIC LOCKING RETRACTOR" FEATURE FOR CHILD SEATS IS STILL FUNCTIONING PROPERLY, IN ADDITION TO OTHER CHECKS FOR PROPER SAFETY BELT SYSTEM FUNCTION. A BELT AND RETRACTOR ASSEMBLY MUST BE REPLACED IF THE SAFETY BELT ASSEMBLY'S "AUTOMATIC LOCKING RETRACTOR" FEATURE, OR ANY OTHER SAFETY BELT FUNCTION, IS NOT OPERATING PROPERLY WHEN CHECKED ACCORDING TO THE PROCEDURES IN THE WORKSHOP MANUAL. FAILURE TO REPLACE THE BELT AND RETRACTOR ASSEMBLY COULD INCREASE THE RISK OF INJURY IN COLLISIONS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Service Precautions > Page 8388 Seat Belt Retractor: Description and Operation NOTE: When installing a new dual locking mode retractor, the retractor should be checked to make sure it is not in the Automatic Locking Retractor (ALR) mode after installation in the stowed position. All outboard continuous-loop, three-point retractor systems, except the driver position, are equipped with the dual locking mode system. The Emergency Locking Retractor (ELR) mode will allow the occupant freedom of movement, locking tight only on hard braking, hard cornering, or an impact of approximately 8 km/h (5 mph). The ELR mode helps to reduce the forward movement of the driver and passengers. The ELR mode is continuously in operation at all seating positions. The ALR portion of this system does not allow the occupant freedom of movement. The ALR mode is used when locking a child seat in an outboard seating position or when a tight belt fit is desired. The ALR mode is disengaged when the webbing is free to move in or out of the retractor. The ALR mode is automatically engaged when the webbing is fully extracted from the retractor and then allowed to retract. As the webbing is retracted back onto the spool, an audible clicking sound is made, indicating that the retractor is in ALR mode. The ALR mode is automatically disengaged when most of the webbing is retracted back onto the spool. WARNING: AFTER ANY VEHICLE COLLISION, THE SAFETY BELT SYSTEM AT ALL OUTBOARD SEATING POSITIONS (EXCEPT DRIVER, WHICH HAS NO "AUTOMATIC LOCKING RETRACTOR" FEATURE) MUST BE CHECKED BY A QUALIFIED TECHNICIAN TO VERIFY THAT THE "AUTOMATIC LOCKING RETRACTOR" FEATURE FOR CHILD SEATS IS STILL FUNCTIONING PROPERLY, IN ADDITION TO OTHER CHECKS FOR PROPER SAFETY BELT SYSTEM FUNCTION. A BELT AND RETRACTOR ASSEMBLY MUST BE REPLACED IF THE SAFETY BELT ASSEMBLY'S "AUTOMATIC LOCKING RETRACTOR" FEATURE OR ANY OTHER SAFETY BELT FUNCTION IS NOT OPERATING PROPERLY WHEN CHECKED ACCORDING TO THE PROCEDURES IN THE WORKSHOP MANUAL. FAILURE TO REPLACE THE BELT AND RETRACTOR ASSEMBLY COULD INCREASE THE RISK OF INJURY IN COLLISIONS. This vehicle has a safety belt system with an energy management feature at the front seating positions to help further reduce the risk of injury in the event of a head-on collision. This safety belt system has a retractor assembly that is designed to pay out webbing in a controlled manner. This feature is designed to help reduce the belt force acting on an occupant's chest. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Service Precautions > Page 8389 Seat Belt Retractor: Testing and Inspection Automatic Locking Retractor - Evaluation of Lockability and Release WARNING: AFTER ANY VEHICLE COLLISION, THE SAFETY BELT SYSTEM AT ALL OUTBOARD SEATING POSITIONS (EXCEPT DRIVER, WHICH HAS NO "AUTOMATIC LOCKING RETRACTOR" FEATURE) MUST BE CHECKED BY A QUALIFIED TECHNICIAN TO VERIFY THAT THE "AUTOMATIC LOCKING RETRACTOR" FEATURE FOR CHILD SEATS IS STILL FUNCTIONING PROPERLY, IN ADDITION TO OTHER CHECKS FOR PROPER SAFETY BELT SYSTEM FUNCTION. A BELT AND RETRACTOR ASSEMBLY MUST BE REPLACED IF THE SAFETY BELT ASSEMBLY'S "AUTOMATIC LOCKING RETRACTOR" FEATURE, OR ANY OTHER SAFETY BELT FUNCTION, IS NOT OPERATING PROPERLY WHEN CHECKED ACCORDING TO THE PROCEDURES IN THE WORKSHOP MANUAL. FAILURE TO REPLACE THE BELT AND RETRACTOR ASSEMBLY COULD INCREASE THE RISK OF INJURY IN COLLISIONS. 1. Extend the safety belt to latch the tongue into the buckle across an empty seat without slack in the safety belt, with the seat in the full down and rearmost position, seat back in an upright position, and if applicable, the D-ring adjusted in the full down position. 2. Pull the shoulder belt to full extension to engage the retractor's Automatic Locking Retractor (ALR) feature. Then allow the belt to retract freely in the ALR mode, and the retractor force set the correct belt tightness. 3. Pull on the shoulder belt to check that the belt has remained in the ALR mode. If the belt is not locked, install a new belt and retractor assembly. The safety belt should remain locked in the ALR mode across an empty seat. 4. To verify that the safety belt still automatically disengages from the ALR mode correctly, with the D-ring adjusted to the full up position, if applicable, unlatch the safety belt tongue from the buckle and allow the safety belt to retract to its stowed position. Pull on the shoulder belt to verify that the retractor assembly has converted automatically out of the ALR mode. If the belt remains locked in the stowed position, a new belt and retractor assembly must be installed. The safety belt should extract freely. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor Seat Belt Retractor: Service and Repair Front Safety Belt Retractor Two-Door Safety Belt Bolt Bit SPECIAL TOOL(S) REMOVAL WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. NOTE: Driver side shown, passenger side similar. 1. Remove the rear quarter trim panel. 2. Remove the safety belt web guide. 1 Remove the bolt. 2 Remove the safety belt web guide from the B-pillar. 3. Remove the front safety belt retractor. 1 Using the special tool, remove the bolt. 2 Remove the front safety belt retractor. INSTALLATION Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 8392 1. Install the front safety belt retractor. 1 Position the front safety belt retractor to the B-pillar. 2 Using the special tool, install the bolt. NOTE: Make sure to tighten nuts and bolts to specification. 2. Install the safety belt web guide. 1 Position the safety belt web guide to the B-pillar. 2 Install the bolt. NOTE: ^ Make sure the safety belt webbing is not twisted prior to installation. ^ Make sure to tighten nuts and bolts to specification. 3. Install the rear quarter trim panel. NOTE: Make sure the safety belt webbing is not twisted prior to installation. 4. Check the active restraint system for correct operation. Four-Door Safety Belt Bolt Bit SPECIAL TOOL(S) REMOVAL WARNING: ALL SAFETY BELT ASSEMBLIES. INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 8393 SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. NOTE: Passenger side shown, driver side similar. 1. Remove the B-pillar trim panel. 2. Remove the front safety belt retractor. 1 Remove the bolt. 2 Using the special tool, remove the bolt. 3 Remove the front safety belt retractor. INSTALLATION 1. Install the front safety belt retractor. 1 Position the front safety belt retractor to the B-pillar. 2 Using the special tool, install the front safety belt retractor bolt. 3 Install the bolt, being careful not to overtighten. NOTE: Make sure to tighten nuts and bolts to specification. 2. Install the B-pillar trim panel. 3. Check the active restraint system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 8394 Seat Belt Retractor: Service and Repair Rear Safety Belt Retractor Four-Door Safety Belt Bolt Bit SPECIAL TOOL(S) REMOVAL WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. NOTE: Passenger side shown, driver side similar. 1. Remove the C-pillar trim panel. 2. Remove the rear safety belt retractor. 1 Using the special tool, remove the bolt. 2 Remove the safety belt retractor. INSTALLATION 1. Install the rear safety belt retractor. 1 Position the safety belt retractor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 8395 2 Using the special tool, install the bolt. NOTE: Make sure to tighten nuts and bolts to specification. 2. Install the C-pillar trim panel. NOTE: Make sure the safety belt webbing is not twisted prior to installation. 3. Check the active restraint system for correct operation. Two-Door Safety Belt Bolt Bit SPECIAL TOOL(S) REMOVAL WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED), CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. NOTE: Driver side shown, passenger side similar. 1. Remove the rear quarter trim panel. 2. Remove the rear safety belt retractor. 1 Using the special tool, remove the bolt. 2 Remove the rear safety belt retractor. INSTALLATION Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 8396 1. Install the rear safety belt retractor. 1 Position the rear safety belt retractor to the B-pillar. 2 Using the special tool, install the bolt. NOTE: Make sure to tighten nuts and bolts to specification. 2. Install the rear quarter trim panel. NOTE: Make sure the safety belt webbing is not twisted prior to installation. 3. Check the active restraint system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Service and Repair > Front Safety Belt Retractor > Page 8397 Seat Belt Retractor: Service and Repair Rear Center Safety Belt Retractor - Four-Door Safety Belt Bolt Bit SPECIAL TOOL(S) REMOVAL WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED) CHILD SAFETY SEAT TETHER ATTACHMENTS AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. 1. Fold the rear seat down to load floor position. 2. Remove the rear safety belt buckle and retractor assembly. 1 Using the special tool, remove the bolt. 2 Remove the rear safety belt buckle and retractor assembly. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Make sure the safety belt webbing is not twisted prior to installation. 2. Check the restraint system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Service and Repair > Page 8398 Seat Belt Bolt Bit Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Warning Timer > Component Information > Description and Operation Seat Belt Warning Timer: Description and Operation Safety Belt Warning Indicator and Chime The warning indicator and chime are reminders to fasten the safety belt. The following conditions will take place: ^ If the safety belt is not buckled before the ignition is turned to the ON position, the chime will turn on for four to eight seconds and the indicator will come on for one to two minutes. ^ If the safety belt is buckled while the indicator is on and the chime is sounding, both the indicator and chime will turn off. ^ If the safety belt is buckled before the ignition is turned to the ON position, neither the indicator nor the chime will turn on. Belt Minder (if equipped) The Belt Minder feature is a supplemental warning to the safety belt warning function. This feature provides additional reminders to the driver that the driver's safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning lamp in the instrument cluster. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications Torque Specifications Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Right Connector View C304 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Right > Page 8408 Connector View C305 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service Precautions > Customer Safety Information Impact Sensor: Customer Safety Information WARNING: MOUNTING ORIENTATION OF THE IMPACT SENSORS AND THE RCM IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE RCM MOUNTING AREA FOR DEFORMATION. INSPECT THE IMPACT SENSOR MOUNTING AREA FOR DAMAGE. IF DAMAGED, THE RCM AND SENSORS MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE MOUNTING AREA OF THE RCM AND IMPACT SENSORS ARE RESTORED TO THE ORIGINAL PRODUCTION CONFIGURATION. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service Precautions > Customer Safety Information > Page 8411 Impact Sensor: Technician Safety Information WARNING: ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, CAUTIONS AND NOTES AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE AND AT THE BEGINNING OF THE REMOVAL PROCEDURE. Refer to Air Bag(s) Arming and Disarming. ^ THE TIGHTENING TORQUE OF THE AIR BAG SIDE IMPACT SENSOR RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service Precautions > Page 8412 Impact Sensor: Description and Operation WARNING: MOUNTING ORIENTATION OF THE IMPACT SENSORS AND THE RCM IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE RCM MOUNTING AREA FOR DEFORMATION. INSPECT THE IMPACT SENSOR MOUNTING AREA FOR DAMAGE. IF DAMAGED, THE RCM AND SENSORS MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE MOUNTING AREA OF THE RCM AND IMPACT SENSORS ARE RESTORED TO THE ORIGINAL PRODUCTION CONFIGURATION. The impact sensors provide data to the RCM for use in calculating impact severity. This is accomplished using various electrical and electro-mechanical sensors located throughout the vehicle. Side impact sensors are located on the LH and RH B-pillars. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation Impact Sensor: Service and Repair Removal and Installation Side Impact Sensor - Driver Side Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Deactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. Refer to Air Bag(s) Arming and Disarming. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8415 3. Remove the LH rear quarter trim panel. 4. Disengage the wire harness pin-type retainers from the B-pillar and position the wire harness out of the way. 5. Position the side impact sensor with the bracket away from the B-pillar. 1 Remove the bolts. 2 Position the side impact sensor with the bracket away from the B-pillar. 6. Remove the side impact sensor. 1 Disconnect the electrical connector. 2 Remove the side impact sensor. INSTALLATION WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, CAUTIONS AND NOTES AT THE BEGINNING OF THE REMOVAL PROCEDURE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8416 1. Connect the side impact sensor electrical connector. 1 Position the side impact sensor. 2 Connect the side impact sensor electrical connector. 2. Install the side impact sensor. 1 Position the side impact sensor with the bracket to the B-pillar. 2 Install the bolts. WARNING: THE TIGHTENING TORQUE OF THE AIR BAG SIDE IMPACT SENSOR RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 3. Connect the battery ground cable. 4. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 5. Disconnect the battery ground cable and wait at least one minute. 6. Route the wire harness and attach the pin-type retainers to the B-pillar. 7. Install the LH rear quarter trim panel. 8. Reactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. Refer to Air Bag(s) Arming and Disarming. 9. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8417 VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 10. Check the active restraint system for correct operation. Side Impact Sensor - Passenger Side Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Deactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. Refer to Air Bag(s) Arming and Disarming. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8418 3. Remove the RH rear quarter trim panel. 4. Disengage the wire harness pin-type retainers from the B-pillar and position the wire harness out of the way. 5. Position the side impact sensor with the bracket away from the B-pillar. 1 Remove the bolts. 2 Position the side impact sensor with the bracket away from the B-pillar. 6. Remove the side impact sensor. 1 Disconnect the electrical connector. 2 Remove the side impact sensor. INSTALLATION WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, CAUTIONS AND NOTES AT THE BEGINNING OF THE REMOVAL PROCEDURE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8419 1. Connect the side impact sensor electrical connector. 1 Position the side impact sensor. 2 Connect the side impact sensor electrical connector. 2. Install the side impact sensor. 1 Position the side impact sensor with the bracket to the B-pillar. 2 Install the bolts. WARNING: THE TIGHTENING TORQUE OF THE AIR BAG SIDE IMPACT SENSOR RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. 3. Connect the battery ground cable. 4. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 5. Disconnect the battery ground cable and wait at least one minute. 6. Route the wire harness and attach the pin-type retainers to the B-pillar. 7. Install the RH rear quarter trim panel. 8. Reactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. Refer to Air Bag(s) Arming and Disarming. 9. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8420 VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 10. Check the active restraint system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8421 Impact Sensor: Service and Repair General Procedures "J" Nut, Restraints Control Module (RCM) and Side Impact Sensor WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both this procedures and Weld Nut Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Impact Sensor before proceeding with the repair. ^ If two or more weld nuts are missing, do not install the "J" nuts as outlined in this procedure. Weld nuts must be installed as outlined in Weld Nut Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Impact Sensor. ^ The following procedure applies to vehicles that have a rectangular hole in the sheet metal that is in close proximity to the missing weld nut. 1. Obtain a "J" nut (part number N623332-S301) or any of the following optional "J" nuts (part numbers: N623342-S101, N800854-S100, N800925-S100). 2. Obtain a 6 mm (0.24 in) grounding screw or equivalent. 3. Install the "J,' nut through the rectangular hole in the sheet metal. 4. Install the crash sensor. NOTE: Be sure the threaded portion of the "J" nut is aligned with the clearance hole in the sheet metal. 5. Tighten the attaching screws to specification. Refer to Torque Specifications. Missing Weld Nut, RCM and Side Impact Sensor WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both this procedure and Weld Nut Repair - "J" Nut, Restraints Control Module (RCM) and Side Impact Sensor before proceeding with the repair. ^ Use only this procedure if two or more weld nuts are missing, do not install the "J" nuts as outlined in Weld Nut Repair - "J" Nut, Restraints Control Module (RCM) and Side Crash Sensor. ^ Radiator support repair shown, others are similar. 1. Obtain a 6 mm (0.24 in) weld nut. 2. Obtain a 6 mm (0.24 in) grounding screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal and Installation > Page 8422 3. Route a sufficient length of copper welding wire through the weld nut clearance hole and back out an adjacent access hole. 4. Feed the copper welding wire through the weld nut, then through a standard flat washer. 5. Secure the flat washer so that it cannot he pulled off the end of the copper welding wire. 6. Pull the copper welding wire back through the clearance hole, allowing the weld nut and flat washer to follow the copper welding wire through. 7. Position the weld nut to the weld nut clearance hole, firmly pulling on the copper welding wire allowing the secured flat washer to hold the weld nut in position. 8. Holding the weld nut securely in place and using a MIG welder, weld in four places around the edge of the weld nut. 9. Metal finish as required. 10. Verify the nut is securely in place. 11. In stall the crash sensor. 12. Tighten the attaching screws to specification. Refer to Torque Specifications. Stripped Weld Nut, RCM and Side Impact Sensor WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 1. Obtain an 8 mm (0.32 in) grounding screw. 2. Drill out the internal threads of the stripped-out weld nut to 7.37 mm (0.29 in) using a letter "L" size drill bit. 3. Position the crash sensor to the vehicle. 4. Install the 8 mm (0.32 in) grounding screw into the drilled-out weld nut. 5. Install the remaining attaching screws. 6. Tighten the attaching screws to specification. Refer to Torque Specifications. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Page 8423 Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Safing Sensor, Air Bag > Component Information > Description and Operation Safing Sensor: Description and Operation The safety sensor is internal to the RCM and is not serviced separately. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams Connector View C323 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair Antenna Cable: Service and Repair REMOVAL NOTE: Antenna lead-in runs from audio unit to connector behind glove box. 1. Remove the audio unit. 2. Remove the antenna lead-in cable. 1 Open the glove box door. 2 Release the tabs and lower the glove box door to the full open position. 3 Release the antenna lead-in cable clips. 4 Disconnect the connector. 5 Separate the antenna cable from the lead-in cable and remove the lead-in cable. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations View 151-9 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 8440 Alarm Module: Diagrams Connector View C274a Connector View C274b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 8441 Alarm Module: Application and ID For further information please see Accessories and Optional Equipment, General Module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Diagrams Connector View C2097 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Diagrams > Page 8445 Alarm System Transponder: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. If equipped, remove the tilt wheel handle 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the upper and lower steering column shrouds. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Diagrams > Page 8446 5. Remove the lower instrument panel steering column cover. 1 Remove the screws. 2 Remove the lower instrument panel steering column cover. 6. Remove the instrument panel steering column opening cover reinforcement. 1 Remove the bolts. 2 Remove the instrument panel steering column opening cover reinforcement. 7. Remove the anti-theft transceiver module. 1 Remove the screw from the bottom of the transceiver module. 2 Disconnect the electrical connector and remove the module. NOTE: Only apply pressure or leverage below the key cylinder lower rib. NOTE: The steering wheel has been removed for clarity. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics Keyless Entry Key-Pad: Technical Service Bulletins Keyless Entry - Keypad Diagnostics TSB 06-15-8 08/07/06 KEYPAD DIAGNOSTICS - DEALER INSTALLED ACCESSORY FORD: 1998-2006 Taurus 1999-2003 Escort 1999-2006 Mustang 2000-2006 Focus 2002-2005 Thunderbird 2005-2006 Five Hundred, Freestyle 2006 Crown Victoria, Fusion 1998-2006 Expedition, Explorer, F-150, Ranger 1999 F-250 Light Duty 1999-2003 Windstar 1999-2006 F-Super Duty 2000-2005 Excursion 2000-2006 E-Series 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004 F-150 Heritage 2004-2006 Freestar LINCOLN: 1998-2006 Town Car 2000-2006 Lincoln LS 2006 Zephyr 1998-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006 Mark LT MERCURY: 1998-2005 Sable 1999-2002 Cougar 2005-2006 Montego 2006 Grand Marquis, Milan 1998-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner ISSUE Some vehicles may experience a concern with the keyless entry keypad. In order to properly diagnose the concern with the keyless entry keypad, it is important to identify whether the keypad is a factory installed style (wired) or a Genuine Ford Accessory (GFA) radio frequency (RF) style keypad. ACTION Use the following Service Procedure to identify GFA RF keypads and provide diagnostic service tips. SERVICE PROCEDURE IDENTIFICATION: 1. Production installed keyless entry keypads are mounted flush with the surface of the vehicle and are wired directly to the module controlling the vehicle's keyless entry system. This style keypad can be diagnosed using the appropriate Workshop Manual (WSM), Section 501-14. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 8452 2. Dealer installed GFA RF keypads are adhesive backed and protrude approximately 1/2" (13 mm) from the surface of the vehicle and there are no specific diagnostics available in the WSM (Figure 1). NOTE THIS RF KEYPAD WAS ALSO US[D IN PRODUCTION ON 2004 F-SUPER DUTY VEHICLES BUILT PRIOR TO 12/3/2003. REFER TO WSM, SECTION 501-14 FOR RF KEYPAD DIAGNOSTICS FOR THESE VEHICLES. GENUINE FORD ACCESSORY KEYPAD DIAGNOSTIC TIPS 1. The keypad operates similarly to a remote keyless entry (RKE) transmitter and is programmed using a similar procedure. Although the RF keypad is not specifically addressed in the WSM, the RKE transmitter programming portion of the WSM, Section 501-14 can be used as a guide NOTE THE 7-8 AND 9-0 BUTTONS ON THE KEYPAD MUST BE PRESSED SIMULTANEOUSLY DURING THE PROCEDURE IN ORDER FOR THE KEYPAD TO BE RECOGNIZED AS AN ADDITIONAL REMOTE TRANSMITTER. Since the GFA RF keypad is essentially another RKE transmitter, the transmitter diagnostic pinpoint tests in the vehicle's WSM can also be referenced even though the buttons serving the lock / unlock functions will differ 2. The GFA RF keypad is serviced as an assembly. The internal battery cannot be replaced separately. 3. If the master code or owner selectable code is lost or forgotten, the GFA RF keypad must be replaced. These codes are not stored in any vehicle module (with the exception of 2004 F-Super Duty vehicles produced prior to 12/3/2003). 4. The GFA RF keypad and all RKE transmitters (the number of transmitters allowable will vary by vehicle) must be reprogrammed together anytime the keypad is replaced, an RKE transmitter is replaced, or the module controlling the keyless entry system on the vehicle (GEM/SJB/VSM/DDM etc.) is replaced. NOTE THERE IS AN EXCEPTION TO TIP 4 FOR VEHICLES EQUIPPED WITH INTEGRATED KEYHEAD TRANSMITTERS (IKTs) (FUSION/MILAN/ZEPHYR). THE GFA RF KEYPADS FOR VEHICLES WITH IKTs MUST BE PROGRAMMED INDEPENDENTLY FROM THE IKTs. TURN THE IGNITION FROM "OFF" TO "RUN" 8 TIMES WITHIN 10 SECONDS, WITH THE 8TH TIME ENDING IN "RUN". THE DOOR LOCKS WILL CYCLE TO CONFIRM ENTERING PROGRAMMING MODE. PRESS THE 7-8 AND 9-0 BUTTON ON THE KEYPAD SIMULTANEOUSLY TO SEND A LOCK SIGNAL. TURN IGNITION TO OFF. THE LOCKS WILL CYCLE AGAIN TO INDICATE THE END OF THE PROGRAMMING MODE. 5. The keypad will normally illuminate for 5 seconds after one or more buttons are pressed, and the illumination will immediately turn off if the 7-8 and 9-0 buttons are pressed simultaneously (lock all doors). The keypad contains an optical sensor and will not illuminate under bright lighting conditions. The keypad may only illuminate briefly in colder temperatures in order to maximize the battery power available to transmit a lock/unlock signal. The temperature at which this occurs will vary depending upon the keypad battery age and condition. Both of these conditions are a normal function of the Power Save Mode and do not indicate a need to replace the keypad. 6. After entering the keypad code, the system may unlock the driver's door, lock it, then unlock it again, and the keypad will not even briefly illuminate. This is the Alert Mode and is an indication that battery power is very low and the keypad must be replaced. 7. The keypad also contains an Anti-scan feature. If the wrong code has been entered 7 times (35 consecutive button presses) the keypad is disabled for one minute and the keypad lamp will flash during this time. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 8453 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 14A626 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Page 8454 Connector View C530 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Page 8455 Keyless Entry Key-Pad: Service and Repair REMOVAL 1. Remove the front door speaker. 2. Disconnect the keyless entry electrical connector. 3. Remove the two wiring harness locators. 4. Release the retaining clip. 5. Remove the keyless entry keypad. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Application and ID Keyless Entry Module: Application and ID For further information please see Accessories and Optional Equipment, General Module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Locations View 151-8 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions Multifunction Electronic Control Modules: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. NOTE: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8464 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number or the component name in one of the the A-Z Component Lists, the Component Location description for that component can easily be found. See: Locations/Component Locations/A-Z Component List Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8465 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8466 the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8467 that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8468 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8469 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8470 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8471 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8472 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8473 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8474 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8475 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8476 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8477 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8478 Systems Overview Wire Color Code Identification Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8479 OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8480 Multifunction Electronic Control Modules: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8481 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8482 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8483 Multifunction Electronic Control Modules: Connector Views Connector View C2100a Connector View C2100b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8484 Multifunction Electronic Control Modules: Electrical Diagrams Diagram 59-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8485 Diagram 59-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8486 Diagram 59-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8487 Diagram 59-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Page 8488 Multifunction Electronic Control Modules: Service Precautions CAUTION: ^ Prior to removal of the Generic Electronic Module (GEM), it is necessary to upload module configuration information to the diagnostic tool. This information needs to be downloaded into the new module once installed. ^ Once the new module is installed, it is necessary to download module configuration information from the appropriate diagnostic tool into the new module. ^ Prior to removal of the Vehicle Security module, it is necessary to upload module configuration information to the appropriate diagnostic equipment. This information needs to be downloaded into the new module once installed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Description and Operation > System Description Multifunction Electronic Control Modules: Description and Operation System Description Module Controlled Functions NOTE: Prior to removal of the Generic Electronic Module (GEM), it is necessary to upload module configuration information to a diagnostic tool. This information needs to be downloaded into the new module once installed. The multifunction module consists of the following: ^ generic electronic module (GEM) ^ central security module The GEM controls the following features: ^ front wiper and washer ^ rear wiper and washer ^ warning chime ^ illuminated entry and interior lighting ^ driver one-touch down power window (optional) ^ battery saver relay ^ door ajar warning indicator lamp ^ safety belt warning indicator lamp The Remote Anti-theft Personality (RAP)/central security module controls the following features: ^ remote keyless entry ^ computer-operated locks Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Description and Operation > System Description > Page 8491 Multifunction Electronic Control Modules: Description and Operation Principles of Operation (How Does It Work?) Generic Electronic Module (Gem) NOTE: Upon installation of a new Generic Electronic Module (GEM), the module must be reconfigured. Refer to Module Communications Network (Information Bus) prior to GEM removal. The GEM receives inputs and delivers outputs to a majority of the electronically controlled features of the vehicle. The GEM constantly monitors the systems under its control and reports a concern in the form of a Diagnostic Trouble Code (DTC). The DTC can be retrieved with a diagnostic tool through the ISO 9141 communication network. The GEM controls the following features: ^ front wiper and washer ^ warning chime ^ battery saver ^ illuminated entry and interior lighting ^ driver one-touch down power window (optional) ^ door ajar warning indicator lamp ^ safety belt warning indicator lamp Vehicle Security Module The central security module controls the following features: ^ remote keyless entry system ^ computer-operated lock system Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Multifunction Electronic Control Modules: Initial Inspection and Diagnostic Overview Generic Electronic Module (GEM) 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Central Junction Box (CJB) fuse: 10 (7.5A) - 20 (7.5A) - 25 (7.5A) - 28 (7.5A) ^ Wiring harness ^ Connector(s) ^ Circuitry 3. If the concern remains after the inspection, connect the diagnostic tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool manual. 5. Carry out the DATA LINK DIAGNOSTICS test. If the diagnostic tool responds with: ^ CKT914, CKT95 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network (Information Bus). ^ NO RESPONSE/NOT EQUIP for GEM, go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM. 6. If the DTCs retrieved are related to the concern, go to the Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Tests and Associated Procedures 7. If no DTCs related to the concern are retrieved, refer to the appropriate vehicle system to continue diagnostics. Vehicle Security Module (VSM) 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Central Junction Box (CJB) fuse: 18 (25A) - 11 (7.5A) ^ Wiring harness ^ Connector(s) ^ Circuitry 3. If the concern remains after the inspection, connect the diagnostic tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool manual. 5. Carry out the DATA LINK DIAGNOSTICS test. If the diagnostic tool responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network (Information Bus). ^ NO RESPONSE/NOT EQUIP for central security module, go to Pinpoint Test B. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry Out self-test diagnostics for the central security module. 6. If the DTCs retrieved are related to the concern, go to the Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Tests and Associated Procedures 7. If no DTCs related to the concern are retrieved, refer to the appropriate vehicle system to continue diagnostics. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8494 Multifunction Electronic Control Modules: Diagnostic Trouble Code Tests and Associated Procedures DTC Chart B1213 - B1325 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8495 DTC Index B1330 - B1345 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8496 DTC Index B1347 - B1446 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8497 DTC Index B1450 - B1611 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8498 DTC Index B1614 - B1934 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8499 DTC Index B1935 - B2440 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8500 DTC Index B2441 - B2477 DTC Index B2477 - P0500 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8501 DTC Index P1804 - U2018 .. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8502 Multifunction Electronic Control Modules: Symptom Related Diagnostic Procedures Symptom Chart Symptom Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8503 Multifunction Electronic Control Modules: Pinpoint Tests A1 - A2 A2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8504 B1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8505 B1 - B2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Generic Electronic Module (GEM) Multifunction Electronic Control Modules: Service and Repair Generic Electronic Module (GEM) REMOVAL 1. Disconnect the battery ground cable. CAUTION: Prior to removal of the Generic Electronic Module (GEM), it is necessary to upload module configuration information to the diagnostic tool. This information needs to be downloaded into the new module once installed. 2. Remove the radio chassis. 3. Remove the center instrument panel finish panel. 1 Remove the screws. 2 Remove the center instrument panel finish panel. ^ Disconnect the electrical connectors. 4. Remove the GEM. 1 Remove the bolt. 2 Disconnect the electrical connectors from the GEM. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Once the new module is installed, it is necessary to download module configuration information from the appropriate diagnostic tool into the new module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Generic Electronic Module (GEM) > Page 8508 Multifunction Electronic Control Modules: Service and Repair Vehicle Security Module REMOVAL CAUTION: Prior to removal of the module, it is necessary to upload module configuration information to the appropriate diagnostic equipment. This information needs to be downloaded into the new module once installed. 1. Disconnect the battery ground cable. 2. Remove the LH rear quarter trim panel. 3. Disconnect the electrical connectors. 4. Remove the central security module. 1 Remove the bolts. 2 Remove the central security module. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Page 8509 Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Subwoofer Connector View C3020 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Subwoofer > Page 8515 Amplifier: Diagrams Subwoofer Amplifier Connector View C466 Connector View C3041a Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Subwoofer > Page 8516 Connector View C3041b Connector View C3041c Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams Radio/Stereo: Diagrams Connector View C290a Connector View C290b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Page 8520 Connector View C290c Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Diagrams Connector View C349 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Diagrams > Page 8524 Remote Control: Service and Repair REMOVAL 1. Disconnect the battery. 2. Remove the console compartment trim panel screws. 3. Remove the console compartment door hinge screw. 4. Remove the console rear panel screws at the top of the panel. 5. Remove the console rear panel screws at the cup holder. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Diagrams > Page 8525 6. Remove the rear integrated control panel screws. 7. Disconnect the floor/panel control arm at the control head. 8. Disconnect the rear blower motor control and rear radio controls electrical connectors. INSTALLATION 1. To install, reverse removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 02-17-3 > Sep > 02 > Audio System - Whining Noise From the Speakers Speaker: Customer Interest Audio System - Whining Noise From the Speakers Article No. 02-17-3 09/02/02 ELECTRICAL - RADIO - SPEAKER WHINE NOISE - VEHICLES WITH "ULTIMATE" PIONEER RADIO SYSTEM PRODUCED ON OR AFTER 3/4/2002 ONLY FORD: 2002 EXPLORER SPORT TRAC ISSUE Some vehicles built on or after 3/4/02, equipped with the Pioneer "Ultimate" 450 watt audio system may exhibit a whine noise from the speakers when using the radio or the CD. The noise changes with engine RPM and is worse with various electrical loads on. This may be due to electrical interference induced into the system by the routing of the power and grounds leads. ACTION To correct the whine noise, the power/ground wiring must be rerouted. To accomplish this, some of the wiring in the vehicle harness will be disabled and an overlay harness will be installed. Order Overlay Harness Kit, 2L2Z-19B113-AA. SERVICE PROCEDURE Refer to the Service Procedures & Illustrations on the instruction sheet included in the kit. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021703A Install Overlay Harness Kit 1.3 Hrs. DEALER CODING CONDITION BASIC PART NO. CODE 19B113 43 OASIS CODES: 203000, 203100, 203200, 207000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 02-17-3 > Sep > 02 > Audio System - Whining Noise From the Speakers Speaker: All Technical Service Bulletins Audio System - Whining Noise From the Speakers Article No. 02-17-3 09/02/02 ELECTRICAL - RADIO - SPEAKER WHINE NOISE - VEHICLES WITH "ULTIMATE" PIONEER RADIO SYSTEM PRODUCED ON OR AFTER 3/4/2002 ONLY FORD: 2002 EXPLORER SPORT TRAC ISSUE Some vehicles built on or after 3/4/02, equipped with the Pioneer "Ultimate" 450 watt audio system may exhibit a whine noise from the speakers when using the radio or the CD. The noise changes with engine RPM and is worse with various electrical loads on. This may be due to electrical interference induced into the system by the routing of the power and grounds leads. ACTION To correct the whine noise, the power/ground wiring must be rerouted. To accomplish this, some of the wiring in the vehicle harness will be disabled and an overlay harness will be installed. Order Overlay Harness Kit, 2L2Z-19B113-AA. SERVICE PROCEDURE Refer to the Service Procedures & Illustrations on the instruction sheet included in the kit. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021703A Install Overlay Harness Kit 1.3 Hrs. DEALER CODING CONDITION BASIC PART NO. CODE 19B113 43 OASIS CODES: 203000, 203100, 203200, 207000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Page 8539 Torque Specifications Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Right Rear Speaker: Diagrams Right Rear Connector View C396 Connector View C802 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Right Rear > Page 8542 Connector View C612 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Right Rear > Page 8543 Connector View C523 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Right Rear > Page 8544 Speaker: Diagrams Left Rear Connector View C395 Connector View C702 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 8545 Speaker: Description and Operation All vehicles are equipped with four premium radio speakers. The front speakers are mounted in the front doors. The rear speakers are mounted in rear doors. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speakers Speaker: Service and Repair Speakers REMOVAL 1. Remove the front door or quarter trim panels. 2. Remove the speakers. 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the speakers. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speakers > Page 8548 Speaker: Service and Repair Speaker - Subwoofer REMOVAL 1. Remove the quarter trim panel. 2. Remove the subwoofer. 1 Disconnect the electrical connector. 2 Remove the screws. 3 Remove the subwoofer. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations View 151-9 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 8553 Alarm Module: Diagrams Connector View C274a Connector View C274b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 8554 Alarm Module: Application and ID For further information please see Accessories and Optional Equipment, General Module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Locations View 151-8 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions Multifunction Electronic Control Modules: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. NOTE: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8560 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number or the component name in one of the the A-Z Component Lists, the Component Location description for that component can easily be found. See: Locations/Component Locations/A-Z Component List Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8561 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8562 the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8563 that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8564 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8565 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8566 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8567 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8568 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8569 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8570 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8571 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8572 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8573 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8574 Systems Overview Wire Color Code Identification Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8575 OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8576 Multifunction Electronic Control Modules: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8577 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8578 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8579 Multifunction Electronic Control Modules: Connector Views Connector View C2100a Connector View C2100b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8580 Multifunction Electronic Control Modules: Electrical Diagrams Diagram 59-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8581 Diagram 59-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8582 Diagram 59-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8583 Diagram 59-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Page 8584 Multifunction Electronic Control Modules: Service Precautions CAUTION: ^ Prior to removal of the Generic Electronic Module (GEM), it is necessary to upload module configuration information to the diagnostic tool. This information needs to be downloaded into the new module once installed. ^ Once the new module is installed, it is necessary to download module configuration information from the appropriate diagnostic tool into the new module. ^ Prior to removal of the Vehicle Security module, it is necessary to upload module configuration information to the appropriate diagnostic equipment. This information needs to be downloaded into the new module once installed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Description and Operation > System Description Multifunction Electronic Control Modules: Description and Operation System Description Module Controlled Functions NOTE: Prior to removal of the Generic Electronic Module (GEM), it is necessary to upload module configuration information to a diagnostic tool. This information needs to be downloaded into the new module once installed. The multifunction module consists of the following: ^ generic electronic module (GEM) ^ central security module The GEM controls the following features: ^ front wiper and washer ^ rear wiper and washer ^ warning chime ^ illuminated entry and interior lighting ^ driver one-touch down power window (optional) ^ battery saver relay ^ door ajar warning indicator lamp ^ safety belt warning indicator lamp The Remote Anti-theft Personality (RAP)/central security module controls the following features: ^ remote keyless entry ^ computer-operated locks Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Description and Operation > System Description > Page 8587 Multifunction Electronic Control Modules: Description and Operation Principles of Operation (How Does It Work?) Generic Electronic Module (Gem) NOTE: Upon installation of a new Generic Electronic Module (GEM), the module must be reconfigured. Refer to Module Communications Network (Information Bus) prior to GEM removal. The GEM receives inputs and delivers outputs to a majority of the electronically controlled features of the vehicle. The GEM constantly monitors the systems under its control and reports a concern in the form of a Diagnostic Trouble Code (DTC). The DTC can be retrieved with a diagnostic tool through the ISO 9141 communication network. The GEM controls the following features: ^ front wiper and washer ^ warning chime ^ battery saver ^ illuminated entry and interior lighting ^ driver one-touch down power window (optional) ^ door ajar warning indicator lamp ^ safety belt warning indicator lamp Vehicle Security Module The central security module controls the following features: ^ remote keyless entry system ^ computer-operated lock system Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Multifunction Electronic Control Modules: Initial Inspection and Diagnostic Overview Generic Electronic Module (GEM) 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Central Junction Box (CJB) fuse: 10 (7.5A) - 20 (7.5A) - 25 (7.5A) - 28 (7.5A) ^ Wiring harness ^ Connector(s) ^ Circuitry 3. If the concern remains after the inspection, connect the diagnostic tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool manual. 5. Carry out the DATA LINK DIAGNOSTICS test. If the diagnostic tool responds with: ^ CKT914, CKT95 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network (Information Bus). ^ NO RESPONSE/NOT EQUIP for GEM, go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM. 6. If the DTCs retrieved are related to the concern, go to the Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Tests and Associated Procedures 7. If no DTCs related to the concern are retrieved, refer to the appropriate vehicle system to continue diagnostics. Vehicle Security Module (VSM) 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Central Junction Box (CJB) fuse: 18 (25A) - 11 (7.5A) ^ Wiring harness ^ Connector(s) ^ Circuitry 3. If the concern remains after the inspection, connect the diagnostic tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool manual. 5. Carry out the DATA LINK DIAGNOSTICS test. If the diagnostic tool responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network (Information Bus). ^ NO RESPONSE/NOT EQUIP for central security module, go to Pinpoint Test B. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry Out self-test diagnostics for the central security module. 6. If the DTCs retrieved are related to the concern, go to the Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Tests and Associated Procedures 7. If no DTCs related to the concern are retrieved, refer to the appropriate vehicle system to continue diagnostics. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8590 Multifunction Electronic Control Modules: Diagnostic Trouble Code Tests and Associated Procedures DTC Chart B1213 - B1325 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8591 DTC Index B1330 - B1345 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8592 DTC Index B1347 - B1446 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8593 DTC Index B1450 - B1611 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8594 DTC Index B1614 - B1934 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8595 DTC Index B1935 - B2440 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8596 DTC Index B2441 - B2477 DTC Index B2477 - P0500 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8597 DTC Index P1804 - U2018 .. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8598 Multifunction Electronic Control Modules: Symptom Related Diagnostic Procedures Symptom Chart Symptom Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8599 Multifunction Electronic Control Modules: Pinpoint Tests A1 - A2 A2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8600 B1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8601 B1 - B2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Generic Electronic Module (GEM) Multifunction Electronic Control Modules: Service and Repair Generic Electronic Module (GEM) REMOVAL 1. Disconnect the battery ground cable. CAUTION: Prior to removal of the Generic Electronic Module (GEM), it is necessary to upload module configuration information to the diagnostic tool. This information needs to be downloaded into the new module once installed. 2. Remove the radio chassis. 3. Remove the center instrument panel finish panel. 1 Remove the screws. 2 Remove the center instrument panel finish panel. ^ Disconnect the electrical connectors. 4. Remove the GEM. 1 Remove the bolt. 2 Disconnect the electrical connectors from the GEM. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Once the new module is installed, it is necessary to download module configuration information from the appropriate diagnostic tool into the new module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Generic Electronic Module (GEM) > Page 8604 Multifunction Electronic Control Modules: Service and Repair Vehicle Security Module REMOVAL CAUTION: Prior to removal of the module, it is necessary to upload module configuration information to the appropriate diagnostic equipment. This information needs to be downloaded into the new module once installed. 1. Disconnect the battery ground cable. 2. Remove the LH rear quarter trim panel. 3. Disconnect the electrical connectors. 4. Remove the central security module. 1 Remove the bolts. 2 Remove the central security module. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Page 8605 Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Application and ID Keyless Entry Module: Application and ID For further information please see Accessories and Optional Equipment, General Module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. NOTE: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8614 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number or the component name in one of the the A-Z Component Lists, the Component Location description for that component can easily be found. See: Locations/Component Locations/A-Z Component List Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8615 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8616 the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8617 that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8618 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8619 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8620 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8621 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8622 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8623 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8624 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8625 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8626 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8627 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8628 Systems Overview Wire Color Code Identification Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8629 OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8630 Trailer Connector: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8631 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8632 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8633 Connector View C439 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8634 Trailer Connector: Electrical Diagrams Diagram 95-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8635 Diagram 95-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8636 Diagram 95-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8637 Diagram 95-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8638 Diagram 95-5 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Customer Interest for Trailer Hitch: > 01-11-10 > Jun > 01 > Trailer Hitch Insufficient Receiver Clearance Trailer Hitch: Customer Interest Trailer Hitch - Insufficient Receiver Clearance Article No. 01-11-10 06/11/01 BODY - FRAME - INSUFFICIENT CLEARANCE IN THE TRAILER HITCH RECEIVER FORD: 2002 EXPLORER MERCURY: 2002 MOUNTAINEER ISSUE Some 2002 Explorer/Mountaineer vehicles equipped with a Class II hitch may exhibit insufficient clearance in the receiver to attach tubular hitch accessories to the vehicle. This may be due to excessive powder coat and e-coat build-up inside the receiver. ACTION To correct this condition, perform the following Service Procedure to remove the excessive paint build-up inside the receiver. SERVICE PROCEDURE CAUTION MAKE SURE TO WEAR PROPER EYE PROTECTION DURING THIS PROCEDURE. 1. Take a 19 mm (3/4") diameter wire brush and attach it to a regular power drill. Insert the wire brush into the receiver tube and remove the black coating on all the sides. 2. Take a 32 mm (1-1/4") flat file and make several passes on the four sides (inside) of the receiver tube until bare metal is visible to the eye. 3. Clean out the coatings and metal dust using an air hose and a piece of cloth. 4. Spray Rustoleum - Gloss Black Spray (obtain locally) inside the receiver tube covering the exposed bare metal inside surface with a thin coat. 5. Inspect the inside of the hitch to make sure that all of the surfaces are covered by the spray paint. 6. Allow paint to dry. 7. Verify repair. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011110A Remove Excessive Paint 0.3 Hr. Build-Up Inside Receiver (Includes Time To Mask Bumper Before Painting Receiver) DEALER CODING CONDITION BASIC PART NO. CODE Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Customer Interest for Trailer Hitch: > 01-11-10 > Jun > 01 > Trailer Hitch Insufficient Receiver Clearance > Page 8647 17D826 07 OASIS CODES: 106000, 108000, 205000, 305000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 01-11-10 > Jun > 01 > Trailer Hitch - Insufficient Receiver Clearance Trailer Hitch: All Technical Service Bulletins Trailer Hitch - Insufficient Receiver Clearance Article No. 01-11-10 06/11/01 BODY - FRAME - INSUFFICIENT CLEARANCE IN THE TRAILER HITCH RECEIVER FORD: 2002 EXPLORER MERCURY: 2002 MOUNTAINEER ISSUE Some 2002 Explorer/Mountaineer vehicles equipped with a Class II hitch may exhibit insufficient clearance in the receiver to attach tubular hitch accessories to the vehicle. This may be due to excessive powder coat and e-coat build-up inside the receiver. ACTION To correct this condition, perform the following Service Procedure to remove the excessive paint build-up inside the receiver. SERVICE PROCEDURE CAUTION MAKE SURE TO WEAR PROPER EYE PROTECTION DURING THIS PROCEDURE. 1. Take a 19 mm (3/4") diameter wire brush and attach it to a regular power drill. Insert the wire brush into the receiver tube and remove the black coating on all the sides. 2. Take a 32 mm (1-1/4") flat file and make several passes on the four sides (inside) of the receiver tube until bare metal is visible to the eye. 3. Clean out the coatings and metal dust using an air hose and a piece of cloth. 4. Spray Rustoleum - Gloss Black Spray (obtain locally) inside the receiver tube covering the exposed bare metal inside surface with a thin coat. 5. Inspect the inside of the hitch to make sure that all of the surfaces are covered by the spray paint. 6. Allow paint to dry. 7. Verify repair. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011110A Remove Excessive Paint 0.3 Hr. Build-Up Inside Receiver (Includes Time To Mask Bumper Before Painting Receiver) DEALER CODING CONDITION BASIC PART NO. CODE Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 01-11-10 > Jun > 01 > Trailer Hitch - Insufficient Receiver Clearance > Page 8653 17D826 07 OASIS CODES: 106000, 108000, 205000, 305000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions Trailer Lamps: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. NOTE: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8658 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number or the component name in one of the the A-Z Component Lists, the Component Location description for that component can easily be found. See: Locations/Component Locations/A-Z Component List Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8659 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8660 the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8661 that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8662 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8663 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8664 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8665 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8666 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8667 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8668 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8669 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8670 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8671 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8672 Systems Overview Wire Color Code Identification Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8673 OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8674 Trailer Lamps: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8675 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8676 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8677 Trailer Lamps: Electrical Diagrams Diagram 95-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8678 Diagram 95-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8679 Diagram 95-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8680 Diagram 95-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8681 Diagram 95-5 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Trailer Lamps: Initial Inspection and Diagnostic Overview 1. Verify the customer concern. 2. Verify the exterior lighting system of the vehicle is operating correctly. If not, refer to the appropriate pinpoint test. 3. Visually inspect for obvious signs of mechanical or electrical damage. VISUAL INSPECTION CHART Electrical ^ Central junction box (CJB) fuse(s): 3 (7.5A) - 7 (7.5A) - 19 (15A) (late production) - 36 (15A) (early production) ^ Circuitry ^ Trailer tow relay ^ Bulb(s) 4. If the fault is not visually evident, determine the symptom and go to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8684 Symptom Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8685 Trailer Lamps: Pinpoint Tests Connector Circuit Reference Refer to Vehicle/Diagrams for schematic and connector information. Y1 Z1 - Z2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8686 Z2 AA1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8687 AB1 AC1 - AC2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8688 AC2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8689 73III Automotive Meter Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Page 8690 73III Automotive Meter Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations Trailer Lighting Relay: Locations Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Page 8694 Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Page 8695 Connector View C2049 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Page 8696 Trailer Lighting Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Page 8697 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. NOTE: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8702 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number or the component name in one of the the A-Z Component Lists, the Component Location description for that component can easily be found. See: Locations/Component Locations/A-Z Component List Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8703 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8704 the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8705 that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8706 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8707 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8708 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8709 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8710 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8711 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8712 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8713 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8714 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8715 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8716 Systems Overview Wire Color Code Identification Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8717 OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8718 Trailer Connector: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8719 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8720 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8721 Connector View C439 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8722 Trailer Connector: Electrical Diagrams Diagram 95-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8723 Diagram 95-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8724 Diagram 95-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8725 Diagram 95-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8726 Diagram 95-5 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair Front Bumper Cover / Fascia: Service and Repair FRONT BUMPER COVER Removal and Installation 1. Remove the radiator grille sight shield. 1. Remove the bolts. 2. Release the retaining clips. 3. Remove the radiator grille sight shield. 2. Remove the two parking lamp assemblies. 1. Remove the two bolts (one each side). 2. Remove the two parking lamp assemblies. - Disconnect the electrical connectors. 3. Remove the two headlamp assemblies. 1. Pull upward to release the four tabs (two each side). 2. Remove the two headlamp assemblies. - Disconnect the electrical connectors. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Page 8733 4. Remove the three lower radiator air deflector bolts. 5. Remove the six fender splash shield screws (three each side). 6. Remove the two front bumper cover bolts from inside the fender opening (one each side). 7. Remove the front bumper cover. - Unclip the six locking tabs. 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Service and Repair Front Bumper Reinforcement: Service and Repair FRONT BUMPER Removal and Installation 1. Remove the front bumper cover. 2. If equipped, remove the two fog lamp assemblies. 1. Disconnect the electrical connectors. 2. Remove the six bolts (three each side). 3. Remove the two fog lamp assemblies. 3. WARNING: To avoid possible injury, support the front bumper before removing the nuts. Remove the four nuts (two each side) and the front bumper. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Bracket > System Information > Service and Repair Rear Bumper Bracket: Service and Repair BUMPER BRACKET - REAR, SPORT TRAC Removal and Installation 1. Remove the rear bumper cover. 2. NOTE: This step may require an assistant. Remove the rear bumper assembly. 1. Remove the four rear bumper bracket to frame nuts (two each side). 2. Remove a stud plate from one side. 3. Remove the rear bumper assembly 3. Remove the rear bumper bracket assembly. 1. Remove the rear bumper beam nuts. 2. Remove the rear bumper hitch plate to rear bumper beam bracket nuts and bolts. 3. Remove the rear bumper bracket assembly. 4. Remove the nuts, stud plate, and separate the rear bumper brackets. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair Rear Bumper Cover / Fascia: Service and Repair REAR BUMPER COVER Special Tool(s) Special Tool(s) Removal and Installation 1. Disconnect the two license plate lamps. 2. Remove the four splash shield screws (two each side). 3. Remove the two rear bumper cover rivets (one each side). 4. NOTE: Align the rear bumper cover to the rear bumper beam guide holes when installing the step pads. Remove the two step pads (one each side). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Page 8744 5. Remove the rear bumper cover. 6. To install, reverse the removal procedure. - Using the special tool, install the new rivets. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Reinforcement > System Information > Service and Repair Rear Bumper Reinforcement: Service and Repair REAR BUMPER - HITCH PLATE, SPORT TRAC Removal and Installation 1. Remove the rear bumper cover. 2. NOTE: - This step may require an assistant. - Disconnect the trailer tow wiring harness. Remove the rear bumper hitch plate. 1. Remove the six nuts and bolts (three each side). 2. Remove the two nuts and bolts (one each side). 3. Remove the rear bumper hitch plate. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair COWL PANEL GRILLE Removal and Installation 1. Disconnect the driver side windshield washer hose from inside the engine compartment. 2. Remove the windshield wiper pivot arms. 1. Slide the clip so the windshield wiper pivot arm will clear the windshield wiper pivot shaft. 2. Pull the windshield wiper pivot arm from the windshield wiper pivot shaft. 3. Remove the cowl grille screw. 4. Remove the driver side cowl grille. - Pull up on the cowl grille to disengage the clips. 5. Remove the passenger side cowl grille. - Pull up on the cowl grille to disengage the clips and disconnect the washer hose. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair Front Door Exterior Handle: Service and Repair Heavy Duty Riveter SPECIAL TOOL(S) REMOVAL NOTE: Front door shown, rear door similar. 1. Remove the door trim panel. 2. Position the watershield aside. 3. Disconnect the exterior handle actuating rod. 1 Open the clip. 2 Disconnect the exterior door handle actuating rod. 4. Remove the rivets and the exterior door handle. INSTALLATION 1. To install, reverse the removal procedure. - Using the special tool, install the rivets. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair > Page 8759 Heavy Duty Riveter Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair Front Door Interior Handle: Service and Repair REMOVAL NOTE: Front door shown, rear door similar. 1. Remove the door trim panel. 2. Position the watershield aside. 3. Remove the interior door handle screws. 4. Remove the interior door handle. 1 Release the actuating rod. 2 Remove the interior door handle. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Adjustments Front Door Hinge: Adjustments NOTE: - Check the rear door hinge adjustment before adjusting the front door hinge. - Explorer Sport Trac shown Explorer Sport similar. 1. Remove the A-pillar lower trim panel. 2. Position the electrical connector mounting bracket aside. 1 Remove the pin-type retainer. 2 Position the electrical connector mounting bracket aside. 3. Mark the position of the front door hinges to use as a reference point. 4. Loosen the two front door hinge to body bolts and nuts just enough to permit movement of the door. NOTE: Position the front door to gain access to the bolts. 5. Adjust the front door alignment to specification. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Adjustments > Page 8766 6. Tighten the front door binge to body bolts and nuts. 7. Install the electrical connector mounting bracket. 1 Install the electrical connector mounting bracket. 2 Install the pin-type retainer. 8. Install the A-pillar lower trim panel. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair Front Door Latch: Service and Repair Heavy Duty Riveter SPECIAL TOOL(S) REMOVAL 1. Remove the interior door handle. 2. Remove the door glass run channel. 1 Remove the bolt. 2 Remove the door glass run channel. Release the wiring harness locator. 3. Remove the screws and position the front door latch aside. - Discard the screws. 4. Release the exterior door handle actuating rod. 1 Open the Clip. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Page 8770 2 Release the exterior door handle actuating rod. 5. Disconnect the front door lock cylinder rod. 6. If equipped, remove the door lock actuator rivet. 7. If equipped, disconnect the door lock actuator electrical connector. 8. Remove the front door latch. 1 Disconnect the door ajar switch electrical connector. 2 Disconnect the ground wire. 3 Remove the front door latch. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Page 8771 9. Remove the front door latch actuating rods. 1 Remove the door lock cylinder actuating rod. 2 Remove the push button lock actuating rod. 3 Remove the interior latch remote control actuating rod. 10. If equipped, remove the door lock actuator. INSTALLATION 1. To install, reverse the removal procedure. - Use the special tool to install the rivet. - If necessary, use Multi-Purpose Grease Spray F5AZ-19G209-AA or equivalent meeting Ford specification ESR-M1C159-A to lubricate the latches. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Page 8772 Heavy Duty Riveter Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair Front Door Panel: Service and Repair REMOVAL High Series Door Trim Panels 1. Disconnect the battery ground cable. 2. Remove the front door window control switch panel. - Disconnect the electrical connectors. All Door Trim Panels 3. Remove the door handle cup screws. 4. Remove the door handle cup. Low Series Door Trim Panels 5. Remove the screw and the window regulator handle. All Door Trim Panels Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Page 8776 6. Remove the front door trim panel. 1 Remove the screws. 2 Remove the front door trim panel. - If equipped, disconnect the exterior mirror control switch electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Page 8777 Seat Belt Bolt Bit Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Service and Repair Front Door Window Glass: Service and Repair Heavy Duty Riverter SPECIAL TOOL(S) REMOVAL 1. Remove the front door trim panel. 2. Remove the front door belt line moulding. 1 Remove the nut. 2 Remove the moulding. CAUTION: Do not strike or force the front door belt line moulding during installation. The front door belt line moulding is made of aluminum and will be damaged. NOTE: During installation, make sure that the front door belt line moulding fits flush with the edge of the sheet metal and the door panel shelf. 3. Remove the interior glass weatherstrip. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Service and Repair > Page 8781 4. Remove the front door window glass rivets. NOTE: Lower the window glass to access the rivets. 5. Remove the front door window glass through the outboard side of the front door. INSTALLATION 1. To install, reverse the removal procedure. ^ Use the special tool to install the rivets. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Diagrams > Left Front Connector View C524 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Diagrams > Left Front > Page 8786 Connector View C608 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Diagrams > Page 8787 Front Door Window Motor: Service Precautions CAUTION: Make sure that no obstructions are present in the power rear window system when carrying out this procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Diagrams > Page 8788 Front Door Window Motor: Service and Repair REMOVAL 1. Remove the front door trim panel. 2. Remove the front door speaker. 1 Remove the screws. 2 Disconnect the electrical connector. 3 Remove the speaker. 3. Remove the water shield. 4. Disconnect the front door window regulator motor electrical connector. 5. Drill a 13 mm (0.52 in) hole using the locator in the door sheet metal as a guide. 6. Remove the bolts and the front door window regulator motor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Diagrams > Page 8789 INSTALLATION 1. To install, reverse the removal procedure. ^ Cycle the door glass to make sure of engagement of the drive mechanism. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair Front Door Window Regulator: Service and Repair Heavy Duty Riverter SPECIAL TOOL(S) REMOVAL 1. Raise the front door window glass to the full up position. 2. Remove the interior door handle. 3. Support the front door window glass. 4. Disconnect the front door window regulator motor electrical connector. 5. Remove the equalizer bracket nuts. 6. Remove the front door window regulator. 1 Remove the rivets. 2 Remove the nut. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Page 8793 7. Remove the front door window regulator motor. 1 Remove the bolts. 2 Remove the front door window regulator motor. INSTALLATION 1. To install, reverse the removal procedure. ^ Use the special tool to install the rivets. ^ Cycle the door glass to make sure of engagement of the drive mechanism. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Page 8794 Heavy Duty Riveter Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair Rear Door Exterior Handle: Service and Repair Heavy Duty Riveter SPECIAL TOOL(S) REMOVAL NOTE: Front door shown, rear door similar. 1. Remove the door trim panel. 2. Position the watershield aside. 3. Disconnect the exterior handle actuating rod. 1 Open the clip. 2 Disconnect the exterior door handle actuating rod. 4. Remove the rivets and the exterior door handle. INSTALLATION 1. To install, reverse the removal procedure. - Using the special tool, install the rivets. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Service and Repair Rear Door Interior Handle: Service and Repair REMOVAL NOTE: Front door shown, rear door similar. 1. Remove the door trim panel. 2. Position the watershield aside. 3. Remove the interior door handle screws. 4. Remove the interior door handle. 1 Release the actuating rod. 2 Remove the interior door handle. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Adjustments Rear Door Hinge: Adjustments 1. Remove the front seat safety belt retractor. 2. Mark the position of the rear door hinges to use as a reference point. 3. Loosen the rear door hinge to body nuts just enough to permit movement of the door. 4. Adjust the rear door alignment to specification. 5. Tighten the rear door hinge to body nuts. 6. Check the front door adjustments. 7. Install the front seat safety belt retractor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Rear Door Latch Rear Door Latch: Service and Repair Rear Door Latch Heavy Duty Riveter SPECIAL TOOL(S) REMOVAL 1. Remove the interior door handle. 2. Disconnect the push button actuating rod. 1 Release the clip. 2 Disconnect the push button actuating rod. 3. Disconnect the exterior door handle actuating rod. 1 Open the clip. 2 Disconnect the exterior door handle actuating rod. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Rear Door Latch > Page 8810 4. Remove the rear door latch screws. - Discard the screws. 5. If equipped, remove the rear door lock actuator rivets. - Disengage the wiring harness locator. 6. If equipped, disconnect the rear door lock actuator electrical connector. 7. Remove the rear door latch. 1 Disconnect the door ajar switch electrical connector. 2 Disconnect the ground wire. 8. Disconnect the rear door latch actuating rods. 1 Disconnect the interior door handle actuating rod. 2 If equipped, remove the door lock actuator. INSTALLATION 1. To install, reverse the removal procedure. - Use the special tool to install the rivets. - If necessary, use Multi-Purpose Grease Spray F5AZ- 19G209-AA or equivalent meeting Ford specification ESR-M1C159-A to lubricate the latches. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Rear Door Latch > Page 8811 Rear Door Latch: Service and Repair Rear Push Button Rod Heavy Duty Riveter SPECIAL TOOL(S) REMOVAL 1. Remove the rear door latch. 2. Remove the rear door push button rod remote control. 1 Remove the rivet. 2 Release the clip and remove the rear door push button rod remote control. 3. Remove the push button rod. 1 Open the clip. 2 Remove the push button rod. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Page 8812 Heavy Duty Riveter Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair Rear Door Panel: Service and Repair REMOVAL High Series Door Trim Panels 1. Remove the rear door window control switch panel. - Disconnect the electrical connector. All Door Trim Panels 2. Remove the door handle cup screws. 3. Remove the door handle cup. Low Series Door Trim Panels 4. Remove the screw and the window regulator handle. All Door Trim Panels Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Page 8816 5. Remove the rear door trim panel. 1 Remove the screw. 2 Remove the rear door trim panel. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Page 8817 Seat Belt Bolt Bit Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > System Information > Service and Repair Rear Door Window Glass: Service and Repair Heavy Duty Riverter SPECIAL TOOL(S) REMOVAL 1. Remove the rear door trim panel. 2. Remove the interior glass weatherstrip. 3. Remove the rear door belt line moulding nut. 4. Remove the rear door belt line moulding. CAUTION: Do not strike or force the front door belt line moulding during the installation. The front door belt line moulding is made of aluminum and will be damaged. NOTE: During installation, make sure that the front door belt line moulding fits flush with the edge of the sheet metal and the door panel shelf. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > System Information > Service and Repair > Page 8821 5. Position aside the water shield. 6. Connect the power window switch. 7. Remove the rear door window glass rivets. ^ Lower the glass approximately two-inches to access the rivets through the holes. 8. Carefully lower the window regulator while holding the glass. ^ Lower the glass. 9. Separate the front of the window run/weatherstrip from the door. 10. Remove the rear door window glass through the outboard side of the rear door. INSTALLATION 1. To install, reverse the removal procedure. ^ Use the special tool to install the rivets. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Technical Service Bulletins > Customer Interest for Rear Door Window Motor: > 07-20-5 > Oct > 07 > Body - Rear Door Window Stuck In Up Position/Inoperative Rear Door Window Motor: Customer Interest Body - Rear Door Window Stuck In Up Position/Inoperative TSB 07-20-5 10/15/07 REAR POWER WINDOW MOTOR INOPERATIVE/STUCK IN THE UP POSITION FORD: 2002-2005 Explorer Sport Trac 2002-2006 Explorer LINCOLN: 2003-2005 Aviator MERCURY: 2002-2006 Mountaineer This article supersedes TSB 07-16-14 to update the Part List. ISSUE Some 2002-2006 Explorer, Mountaineer and 2002-2005 Explorer Sport Trac, and 2003-2005 Aviator vehicles built before 1/23/2006 may experience a rear power window that sticks in the up position. This condition can be intermittent and may be due to the power motor which temporarily locks up. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Use the current Workshop Manual (WSM), Section 501-11 procedure to remove the door panel and inspect the window regulator for damaged parts. 2. If any damage part or parts are found replace the regulator assembly. 3. If no damaged parts are found on the regulator assembly, replace the window regulator motor using WSM, Section 501-11. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072005A 2002-2005 Explorer Sport 0.9 Hr. Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B 27406B8, 27406B9) 072005B 2002-2005 Explorer Sport 1.6 Hrs. Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Technical Service Bulletins > Customer Interest for Rear Door Window Motor: > 07-20-5 > Oct > 07 > Body - Rear Door Window Stuck In Up Position/Inoperative > Page 8830 To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9) 072005C 2002-2006 0.4 Hr. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B, 27406B8, 27406B9) 072005D 2002-2006 0.7 Hr. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9) 072005E 2002-2006 0.6 Hr. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B, 27406B8, 27406B9) 07200SF 2002-2006 1.1 Hrs. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9) DEALER CODING CONDITION BASIC PART NO. CODE 7823394 07 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Motor: > 07-20-5 > Oct > 07 > Body - Rear Door Window Stuck In Up Position/Inoperative Rear Door Window Motor: All Technical Service Bulletins Body - Rear Door Window Stuck In Up Position/Inoperative TSB 07-20-5 10/15/07 REAR POWER WINDOW MOTOR INOPERATIVE/STUCK IN THE UP POSITION FORD: 2002-2005 Explorer Sport Trac 2002-2006 Explorer LINCOLN: 2003-2005 Aviator MERCURY: 2002-2006 Mountaineer This article supersedes TSB 07-16-14 to update the Part List. ISSUE Some 2002-2006 Explorer, Mountaineer and 2002-2005 Explorer Sport Trac, and 2003-2005 Aviator vehicles built before 1/23/2006 may experience a rear power window that sticks in the up position. This condition can be intermittent and may be due to the power motor which temporarily locks up. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Use the current Workshop Manual (WSM), Section 501-11 procedure to remove the door panel and inspect the window regulator for damaged parts. 2. If any damage part or parts are found replace the regulator assembly. 3. If no damaged parts are found on the regulator assembly, replace the window regulator motor using WSM, Section 501-11. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072005A 2002-2005 Explorer Sport 0.9 Hr. Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B 27406B8, 27406B9) 072005B 2002-2005 Explorer Sport 1.6 Hrs. Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Motor: > 07-20-5 > Oct > 07 > Body - Rear Door Window Stuck In Up Position/Inoperative > Page 8836 To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9) 072005C 2002-2006 0.4 Hr. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B, 27406B8, 27406B9) 072005D 2002-2006 0.7 Hr. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9) 072005E 2002-2006 0.6 Hr. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B, 27406B8, 27406B9) 07200SF 2002-2006 1.1 Hrs. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9) DEALER CODING CONDITION BASIC PART NO. CODE 7823394 07 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Diagrams > Left Connector View C703 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Diagrams > Left > Page 8839 Connector View C351 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Diagrams > Left > Page 8840 Connector View C803 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Diagrams > Page 8841 Rear Door Window Motor: Service Precautions CAUTION: Make sure that no obstructions are present in the power rear window system when carrying out this procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Service and Repair > Rear Door Window Regulator Motor Rear Door Window Motor: Service and Repair Rear Door Window Regulator Motor REMOVAL 1. Remove the rear door window regulator. 2. Remove the rear door window regulator motor. 1 Remove the bolts. 2 Remove the rear door window regulator motor. INSTALLATION 1. To install, reverse the removal procedure. ^ Cycle the door glass to make sure of engagement of the drive mechanism. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Service and Repair > Rear Door Window Regulator Motor > Page 8844 Rear Door Window Motor: Service and Repair Rear Window Glass Motor REMOVAL NOTE: ^ The power rear window motor can be removed and a new one installed without removing the seat or trim panel. ^ When the power rear window motor is removed and installed, the motor must be initialized. 1. Fold down the passenger rear seat back. 2. Open the luggage compartment trim panel access door. 3. Remove the spare tire jack and handle assembly. 4. Position the carpet aside and position the water shield back from the rear window glass motor to access bolts. NOTE: The rear window glass water shield uses a reusable butyl rubber adhesive. A new water shield does not have to be installed unless it is damaged or if the butyl rubber adhesive does not adhere to a section of the sheet metal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Service and Repair > Rear Door Window Regulator Motor > Page 8845 5. Remove the rear window motor. 1 Disconnect the electrical connector. 2 Remove the bolts. 3 Remove the rear window glass motor. CAUTION: Use care not to damage the drum housing when removing the rear window glass motor. NOTE: Apply pressure to the drum while removing the rear window motor to avoid extraction of the drum with the motor. INSTALLATION 1. To install, reverse the removal procedure. NOTE: The rear window motor must be initialized after a repair is carried out. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Service and Repair > Rear Door Window Regulator Motor > Page 8846 Rear Door Window Motor: Service and Repair Rear Window Motor Initialization CAUTION: Make sure that no obstructions are present in the power rear window system when carrying out this procedure. NOTE: ^ This procedure must be carried out when repairs are performed on any part of the power rear window system including when: the power rear window motor is removed from the window regulator drum housing, a new power rear motor is installed, a new power rear window regulator is installed, a new power rear window module is installed, and any operation in which grease or lubricants are applied to the power rear window system. ^ All power rear window components (window glass module, window regulator, window motor, and glass runs) must be installed and torqued to specification before carrying out this procedure. ^ Steps 1-6 must be completed within 30 seconds. The entire procedure must be completed within five minutes. ^ Once the ignition key is turned to the ON position in Step 6, it must remain on until the entire procedure is completed. ^ Steps 7 and 9 require that the power rear window control switch be held in the closed position until the power rear window motor stalls the window in the upper header seal. Step 8 requires that the window control switch be momentarily turned to the open position. 1. Start with the ignition in the OFF position. 2. Turn the ignition to the ON position. 3. Press the power rear window control switch vent button six times. 4. Turn the ignition to the OFF position. 5. Press the power rear window control switch vent button six times. 6. Turn the ignition to the ON position. The power rear window will move up-down-up-down approximately 20 mm (0.8 in). This movement indicates that the power rear window motor has entered initialized mode. 7. Rotate and hold the power rear window control switch to the closed position until the window stalls in the upper header seal. 8. Momentarily rotate the power rear window control switch to the open position and release. The power rear window will carry out a one-touch down operation until the window stalls at the bottom of the travel stop designed into the window regulator. 9. Rotate and hold the power rear window control switch to the closed position until the window stalls into the upper header seal. Once this operation is complete, the window will move up-down-up-down approximately 20 mm (0.8 in). This movement indicates that the power rear window motor has been successfully initialized. 10. Verify correct operation of the power rear window by moving the window to the fully open, vent, then fully closed positions. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Technical Service Bulletins > Customer Interest for Rear Door Window Regulator: > 07-20-5 > Oct > 07 > Body - Rear Door Window Stuck In Up Position/Inoperative Rear Door Window Regulator: Customer Interest Body - Rear Door Window Stuck In Up Position/Inoperative TSB 07-20-5 10/15/07 REAR POWER WINDOW MOTOR INOPERATIVE/STUCK IN THE UP POSITION FORD: 2002-2005 Explorer Sport Trac 2002-2006 Explorer LINCOLN: 2003-2005 Aviator MERCURY: 2002-2006 Mountaineer This article supersedes TSB 07-16-14 to update the Part List. ISSUE Some 2002-2006 Explorer, Mountaineer and 2002-2005 Explorer Sport Trac, and 2003-2005 Aviator vehicles built before 1/23/2006 may experience a rear power window that sticks in the up position. This condition can be intermittent and may be due to the power motor which temporarily locks up. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Use the current Workshop Manual (WSM), Section 501-11 procedure to remove the door panel and inspect the window regulator for damaged parts. 2. If any damage part or parts are found replace the regulator assembly. 3. If no damaged parts are found on the regulator assembly, replace the window regulator motor using WSM, Section 501-11. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072005A 2002-2005 Explorer Sport 0.9 Hr. Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B 27406B8, 27406B9) 072005B 2002-2005 Explorer Sport 1.6 Hrs. Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Technical Service Bulletins > Customer Interest for Rear Door Window Regulator: > 07-20-5 > Oct > 07 > Body - Rear Door Window Stuck In Up Position/Inoperative > Page 8855 To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9) 072005C 2002-2006 0.4 Hr. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B, 27406B8, 27406B9) 072005D 2002-2006 0.7 Hr. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9) 072005E 2002-2006 0.6 Hr. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B, 27406B8, 27406B9) 07200SF 2002-2006 1.1 Hrs. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9) DEALER CODING CONDITION BASIC PART NO. CODE 7823394 07 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > 07-20-5 > Oct > 07 > Body - Rear Door Window Stuck In Up Position/Inoperative Rear Door Window Regulator: All Technical Service Bulletins Body - Rear Door Window Stuck In Up Position/Inoperative TSB 07-20-5 10/15/07 REAR POWER WINDOW MOTOR INOPERATIVE/STUCK IN THE UP POSITION FORD: 2002-2005 Explorer Sport Trac 2002-2006 Explorer LINCOLN: 2003-2005 Aviator MERCURY: 2002-2006 Mountaineer This article supersedes TSB 07-16-14 to update the Part List. ISSUE Some 2002-2006 Explorer, Mountaineer and 2002-2005 Explorer Sport Trac, and 2003-2005 Aviator vehicles built before 1/23/2006 may experience a rear power window that sticks in the up position. This condition can be intermittent and may be due to the power motor which temporarily locks up. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Use the current Workshop Manual (WSM), Section 501-11 procedure to remove the door panel and inspect the window regulator for damaged parts. 2. If any damage part or parts are found replace the regulator assembly. 3. If no damaged parts are found on the regulator assembly, replace the window regulator motor using WSM, Section 501-11. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072005A 2002-2005 Explorer Sport 0.9 Hr. Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B 27406B8, 27406B9) 072005B 2002-2005 Explorer Sport 1.6 Hrs. Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > 07-20-5 > Oct > 07 > Body - Rear Door Window Stuck In Up Position/Inoperative > Page 8861 To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9) 072005C 2002-2006 0.4 Hr. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B, 27406B8, 27406B9) 072005D 2002-2006 0.7 Hr. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9) 072005E 2002-2006 0.6 Hr. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B, 27406B8, 27406B9) 07200SF 2002-2006 1.1 Hrs. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9) DEALER CODING CONDITION BASIC PART NO. CODE 7823394 07 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > Page 8862 Rear Door Window Regulator: By Symptom Technical Service Bulletin # 07-20-5 Date: 071015 Body - Rear Door Window Stuck In Up Position/Inoperative TSB 07-20-5 10/15/07 REAR POWER WINDOW MOTOR INOPERATIVE/STUCK IN THE UP POSITION FORD: 2002-2005 Explorer Sport Trac 2002-2006 Explorer LINCOLN: 2003-2005 Aviator MERCURY: 2002-2006 Mountaineer This article supersedes TSB 07-16-14 to update the Part List. ISSUE Some 2002-2006 Explorer, Mountaineer and 2002-2005 Explorer Sport Trac, and 2003-2005 Aviator vehicles built before 1/23/2006 may experience a rear power window that sticks in the up position. This condition can be intermittent and may be due to the power motor which temporarily locks up. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Use the current Workshop Manual (WSM), Section 501-11 procedure to remove the door panel and inspect the window regulator for damaged parts. 2. If any damage part or parts are found replace the regulator assembly. 3. If no damaged parts are found on the regulator assembly, replace the window regulator motor using WSM, Section 501-11. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072005A 2002-2005 Explorer Sport 0.9 Hr. Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B 27406B8, 27406B9) 072005B 2002-2005 Explorer Sport 1.6 Hrs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > Page 8863 Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9) 072005C 2002-2006 0.4 Hr. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B, 27406B8, 27406B9) 072005D 2002-2006 0.7 Hr. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9) 072005E 2002-2006 0.6 Hr. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B, 27406B8, 27406B9) 07200SF 2002-2006 1.1 Hrs. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9) DEALER CODING CONDITION BASIC PART NO. CODE 7823394 07 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > Page 8864 Disclaimer Technical Service Bulletin # 07-20-5 Date: 071015 Body - Rear Door Window Stuck In Up Position/Inoperative TSB 07-20-5 10/15/07 REAR POWER WINDOW MOTOR INOPERATIVE/STUCK IN THE UP POSITION FORD: 2002-2005 Explorer Sport Trac 2002-2006 Explorer LINCOLN: 2003-2005 Aviator MERCURY: 2002-2006 Mountaineer This article supersedes TSB 07-16-14 to update the Part List. ISSUE Some 2002-2006 Explorer, Mountaineer and 2002-2005 Explorer Sport Trac, and 2003-2005 Aviator vehicles built before 1/23/2006 may experience a rear power window that sticks in the up position. This condition can be intermittent and may be due to the power motor which temporarily locks up. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Use the current Workshop Manual (WSM), Section 501-11 procedure to remove the door panel and inspect the window regulator for damaged parts. 2. If any damage part or parts are found replace the regulator assembly. 3. If no damaged parts are found on the regulator assembly, replace the window regulator motor using WSM, Section 501-11. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072005A 2002-2005 Explorer Sport 0.9 Hr. Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B 27406B8, 27406B9) 072005B 2002-2005 Explorer Sport 1.6 Hrs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > Page 8865 Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9) 072005C 2002-2006 0.4 Hr. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B, 27406B8, 27406B9) 072005D 2002-2006 0.7 Hr. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9) 072005E 2002-2006 0.6 Hr. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B, 27406B8, 27406B9) 07200SF 2002-2006 1.1 Hrs. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9) DEALER CODING CONDITION BASIC PART NO. CODE 7823394 07 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > Page 8866 Disclaimer Technical Service Bulletin # 07-20-5 Date: 071015 Body - Rear Door Window Stuck In Up Position/Inoperative TSB 07-20-5 10/15/07 REAR POWER WINDOW MOTOR INOPERATIVE/STUCK IN THE UP POSITION FORD: 2002-2005 Explorer Sport Trac 2002-2006 Explorer LINCOLN: 2003-2005 Aviator MERCURY: 2002-2006 Mountaineer This article supersedes TSB 07-16-14 to update the Part List. ISSUE Some 2002-2006 Explorer, Mountaineer and 2002-2005 Explorer Sport Trac, and 2003-2005 Aviator vehicles built before 1/23/2006 may experience a rear power window that sticks in the up position. This condition can be intermittent and may be due to the power motor which temporarily locks up. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Use the current Workshop Manual (WSM), Section 501-11 procedure to remove the door panel and inspect the window regulator for damaged parts. 2. If any damage part or parts are found replace the regulator assembly. 3. If no damaged parts are found on the regulator assembly, replace the window regulator motor using WSM, Section 501-11. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072005A 2002-2005 Explorer Sport 0.9 Hr. Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B 27406B8, 27406B9) 072005B 2002-2005 Explorer Sport 1.6 Hrs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > Page 8867 Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9) 072005C 2002-2006 0.4 Hr. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B, 27406B8, 27406B9) 072005D 2002-2006 0.7 Hr. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9) 072005E 2002-2006 0.6 Hr. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B, 27406B8, 27406B9) 07200SF 2002-2006 1.1 Hrs. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9) DEALER CODING CONDITION BASIC PART NO. CODE 7823394 07 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > Page 8868 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Technical Service Bulletins > Page 8869 Rear Door Window Regulator: Service and Repair Heavy Duty Riverter SPECIAL TOOL(S) REMOVAL 1. Raise and support the rear door window glass to the full up position. 2. Remove the interior door handle. 3. Remove the rear door speaker. 1 Remove the screws. 2 Disconnect the electrical connector. 3 Remove the speaker. 4. Remove the water shield. 5. Disconnect the rear door window regulator motor electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Technical Service Bulletins > Page 8870 6. Remove the rear door window regulator rivets. 7. Remove the rear door window regulator. ^ Slide the regulator arms off of the window glass track. INSTALLATION 1. To install, reverse the removal procedure. ^ Use the special tool to install the rivets. ^ Cycle the door glass to make sure of engagement of the drive mechanism. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Technical Service Bulletins > Page 8871 Heavy Duty Riveter Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair Hood Latch: Service and Repair REMOVAL 1. Remove the radiator grille sight shield. 1 Remove the bolts. 2 Release the retaining clips. 3 Remove the radiator grille sight shield. 2. Remove the bolts and position the hood latch aside. 3. Remove the hood latch. 1 Release the cable conduit. 2 Release the hood latch cable. INSTALLATION Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Page 8876 1. Install the hood latch cable. 1 Install the hood latch cable. 2 Install the cable conduit. 2. Position the hood latch and install the bolts. 3. Align the hood latch. 1 Loosen the hood latch bolts enough to allow for movement of the hood latch. 2 Align the hood latch with the hood latch striker. 4. Tighten the hood latch bolts. 5. Verify the hood latch striker is fully engaging the hood latch. - If necessary, use Multi-Purpose Grease Spray F5AZ-19G209-AA or equivalent meeting Ford specification ESR-M1C159-A to lubricate the latch. - Repeat the install procedure as necessary to make sure the hood latch is aligned correctly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Page 8877 6. Install the radiator grille sight shield. 1 Position the sight shield. 2 Lock the clips. 3 Install the bolts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release > Component Information > Service and Repair Hood Latch Release: Service and Repair REMOVAL 1. Remove the hood latch. 2. Remove the hood latch release handle screws. 3. Release the hood latch release cable. 1 Disconnect the cable conduit. 2 Release the cable. 4. Remove the two hood latch release handle cable locators. 5. Pull the hood latch release handle cable towards the engine compartment and remove the cable. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Technical Service Bulletins > Customer Interest for Hood Latch Release Cable: > 05-10-3 > May > 05 > Interior - Accelerator Pedal Vibration at 1500-1800 RPM Hood Latch Release Cable: Customer Interest Interior - Accelerator Pedal Vibration at 1500-1800 RPM TSB 05-10-3 05/30/05 ACCELERATOR PEDAL VIBRATION/BUZZ AT 1500-1800 RPM FORD: 2001-2005 Explorer Sport Trac ISSUE Some 2001-2005 Explorer Sport Trac vehicles may exhibit the accelerator pedal vibrating or buzzing at 1500-1800 RPM. ACTION Ensure the accelerator cable and the hood release cables are not contacting the # 6 spark plug wire. Reposition cables as needed. Also, ensure that the accelerator cable is secure in the retention clip, and that the clip's spring tensioner is on top. Refer to Figure 1 (incorrect position) and Figure 2 (correct position). WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9A758 43 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Technical Service Bulletins > Customer Interest for Hood Latch Release Cable: > 05-10-3 > May > 05 > Interior - Accelerator Pedal Vibration at 1500-1800 RPM > Page 8889 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hood Latch Release Cable: > 05-10-3 > May > 05 > Interior - Accelerator Pedal Vibration at 1500-1800 RPM Hood Latch Release Cable: All Technical Service Bulletins Interior - Accelerator Pedal Vibration at 1500-1800 RPM TSB 05-10-3 05/30/05 ACCELERATOR PEDAL VIBRATION/BUZZ AT 1500-1800 RPM FORD: 2001-2005 Explorer Sport Trac ISSUE Some 2001-2005 Explorer Sport Trac vehicles may exhibit the accelerator pedal vibrating or buzzing at 1500-1800 RPM. ACTION Ensure the accelerator cable and the hood release cables are not contacting the # 6 spark plug wire. Reposition cables as needed. Also, ensure that the accelerator cable is secure in the retention clip, and that the clip's spring tensioner is on top. Refer to Figure 1 (incorrect position) and Figure 2 (correct position). WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9A758 43 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hood Latch Release Cable: > 05-10-3 > May > 05 > Interior - Accelerator Pedal Vibration at 1500-1800 RPM > Page 8895 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair Liftgate Window Glass: Service and Repair REMOVAL 1. Open the liftgate glass. 2. Remove the two heated rear window electrical connector covers. 3. Disconnect the two heated rear window electrical connectors. 4. Remove the two liftgate lifting cylinder pins. NOTE: An assistant may be needed to carry out this step. 5. Remove the liftgate window glass. 1 Position the liftgate trim panel aside. 2 Remove the access the covers and the liftgate window hinge nuts. NOTE: An assistant may be needed to carry out this step. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair > Page 8900 6. Remove the liftgate window glass. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Diagrams Connector View C457 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams Connector View C456 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams > Page 8907 Power Trunk / Liftgate Lock Switch: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams > Page 8908 Liftgate Door Lock Switch Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch Trunk / Liftgate Latch: Service and Repair Liftgate Latch REMOVAL 1. Disconnect the battery ground cable. 2. Remove the liftgate trim panel. 3. Remove the air escape vent panel. 1 Remove the pin-type retainers. 2 Remove the air escape vent panel. 4. Remove the watershield. 5. Disconnect the liftgate latch release rod from the liftgate latch remote control. 1 Open the clip. 2 Disconnect the liftgate latch release rod. 6. Remove the liftgate latch. 1 Remove the bolts. 2 Disconnect the electrical connector. 3 Remove the liftgate latch and the liftgate release rod. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch > Page 8913 INSTALLATION 1. To install, reverse the removal procedure. - If necessary, use Multi-Purpose Grease Spray F5AZ-19G209-AA or equivalent meeting Ford specification ESR-M1C159-A to lubricate the latches. NOTE: - If installation of a new liftgate latch release rod is necessary, be sure to match the color coded rods for correct installation. - Make sure the liftgate latch release rod is not preloading the latch. It should be clipped in a relaxed state with no slack. - Position the liftgate latch release rod by pushing outboard to remove the slack. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch > Page 8914 Trunk / Liftgate Latch: Service and Repair Liftgate Latch - Window REMOVAL 1. Disconnect the battery ground cable. 2. Open the liftgate window glass. 3. Remove the liftgate trim panel. 4. Remove the air escape vent panel. 1 Remove the pin-type retainers. 2 Remove the air escape vent panel. 5. Remove the watershield. 6. Disconnect the liftgate window latch actuating rod. 1 Open the clip. 2 Disconnect the liftgate window latch actuating rod. 7. Disconnect the liftgate window ajar switch electrical connector and remove the nuts. NOTE: Mark the position of the liftgate window latch prior to removing the nuts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch > Page 8915 8. Remove the liftgate window latch. INSTALLATION 1. Position the liftgate window latch and loosely install the nuts. 2. Move the liftgate window glass to the closed position. 3. Adjust the liftgate window latch. - Set the liftgate window glass flushness to 1.5 mm (0.06 in) under flush. 4. Tighten the liftgate window latch nuts. - If necessary, use Multi-Purpose Grease Spray F5AZ-19G209-AA or equivalent meeting Ford specification ESR-M1C159-A to lubricate the latches. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch > Page 8916 5. Connect the liftgate window latch actuating rod. 1 Connect the liftgate window latch actuating rod. 2 Lock the clip. 6. Verify the liftgate window glass adjustment. 7. Install the watershield. 8. Install the air escape vent panel. 1 Position the air escape vent panel. 2 Install the pin-type retainers. 9. Install the liftgate trim panel. 10. Connect the battery ground cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch > Page 8917 Trunk / Liftgate Latch: Service and Repair Liftgate Latch Remote Control REMOVAL 1. Remove the liftgate latch actuator. 2. Remove the liftgate latch remote control from the liftgate. - Transfer parts as necessary. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Make sure the liftgate handle actuating rod is not preloading the liftgate latch remote control. It should be clipped in a relaxed state with no slack. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Service and Repair Trunk / Liftgate Lock Cylinder: Service and Repair REMOVAL NOTE: Individual lock cylinders are repaired by discarding the inoperative cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle; 1. Remove the liftgate latch remote control. 2. Remove the liftgate lock cylinder. 1 Remove the nuts. 2 Remove the liftgate lock cylinder. If equipped, disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Release Lever > Component Information > Service and Repair Trunk / Liftgate Release Lever: Service and Repair Heavy Duty Riveter SPECIAL TOOL(S) REMOVAL 1. Remove the liftgate trim panel. 2. Remove the air escape vent panel. 1 Remove the pin-type retainers. 2 Remove the air escape vent panel. 3. Position the watershield aside. 4. Disconnect the liftgate release handle actuating rod. 1 Open the clip. 2 Disconnect the liftgate release handle actuating rod. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Release Lever > Component Information > Service and Repair > Page 8924 5. Remove the license plate lamp shield. 1 Remove the screws. 2 Remove the license plate lamp shield. 6. Remove the liftgate release handle. 1 Remove the rivets. 2 Remove the liftgate release handle. INSTALLATION 1. To install, reverse the removal procedure. - Using the special tool, install the rivets. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Release Lever > Component Information > Service and Repair > Page 8925 Heavy Duty Riveter Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid > Component Information > Service and Repair Trunk / Liftgate Solenoid: Service and Repair REMOVAL 1. Remove the liftgate window latch. 2. Disconnect the liftgate latch release rods. 1 Open the clips. 2 Disconnect the liftgate latch release rods. 3. Disconnect the liftgate release handle actuating rod. 1 Open the clip. 2 Disconnect the liftgate release handle actuating rod. 4. Disconnect the lock cylinder actuating rod. 1 Open the clip. 2 Disconnect the lock cylinder actuating rod. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid > Component Information > Service and Repair > Page 8929 5. Remove the liftgate lock remote control bolt. 6. Disconnect the liftgate lock actuator electrical connector. 7. Remove the liftgate lock actuator nuts. 8. Move the liftgate latch remote control to the LH opening and remove the liftgate latch actuator. INSTALLATION 1. Connect and position the liftgate latch actuator. 2. Install the liftgate latch actuator nuts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid > Component Information > Service and Repair > Page 8930 3. Connect the liftgate latch actuator electrical connector. 4. Position the liftgate latch remote control. 5. Loosely install the liftgate latch remote control bolt. 6. Position the liftgate window latch and loosely install the nuts and connect the electrical connector. 7. Move the liftgate window glass to the closed position. 8. Adjust the liftgate window latch. - Set the liftgate window glass flushness to 1.5 mm (0.06 in) under flush. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid > Component Information > Service and Repair > Page 8931 9. Tighten the liftgate window latch nuts. - If necessary, use Multi-Purpose Grease Spray F5AZ-19G209-AA or equivalent meeting Ford specification ESR-M1C159-A to lubricate the latches. 10. Connect the liftgate window latch actuating rod. 1 Connect the liftgate window latch actuating rod. 2 Lock the clip. 11. Verify the liftgate window glass adjustment. 12. Tighten the liftgate latch remote control bolt. 13. Connect the lock cylinder actuating rod. 1 Position the lock cylinder actuating rod. 2 Close the clip. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid > Component Information > Service and Repair > Page 8932 NOTE: Be sure the bell crank of the liftgate latch remote control is in the unlocked position (upward) for correct lock cylinder rod length. 14. Connect the liftgate release handle actuating rod. 1 Position the liftgate release handle actuating rod. 2 Close the clip. NOTE: Make sure the liftgate release handle actuating rod is not preloading the liftgate latch remote control. It should be clipped in a relaxed state with no slack. 15. Connect the liftgate latch release rods. 1 Position the liftgate latch release rods by pushing outboard to remove the slack. 2 Close the clips. NOTE: Make sure the latch release rods are not preloading the liftgate latch. They should be clipped in a relaxed state with no slack. 16. Install the watershield 17. Install the air escape vent panel. 1 Position the air escape vent panel. 2 Install the pin-type retainers. 18. Install the liftgate trim panel. 19. Connect the battery ground cable. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair COWL PANEL GRILLE Removal and Installation 1. Disconnect the driver side windshield washer hose from inside the engine compartment. 2. Remove the windshield wiper pivot arms. 1. Slide the clip so the windshield wiper pivot arm will clear the windshield wiper pivot shaft. 2. Pull the windshield wiper pivot arm from the windshield wiper pivot shaft. 3. Remove the cowl grille screw. 4. Remove the driver side cowl grille. - Pull up on the cowl grille to disengage the clips. 5. Remove the passenger side cowl grille. - Pull up on the cowl grille to disengage the clips and disconnect the washer hose. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair Front Fender Liner: Service and Repair FENDER SPLASH SHIELD Removal and Installation Both Sides 1. Remove the fender splash shield front bolts. 2. Remove the fender splash shield screws. LH Side 3. From inside the engine compartment, disconnect the wiring harness retainers from the fender splash shield. 4. Remove the ABS module nut. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair > Page 8942 RH Side 5. Position the vacuum reservoir aside. 1. Remove the bolts. 2. Position the vacuum reservoir aside. 6. Remove the fender splash shield bolts. Both Sides 7. Remove the fender splash shield. 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation Body / Frame Mount Bushing: Description and Operation FRAME AND BODY MOUNTING Explorer Sport/Sport Trac Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation > Page 8947 Explorer Sport/Sport Trac Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation > Page 8948 Explorer Sport/Sport Trac Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation > Page 8949 Explorer Sport Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation > Page 8950 Explorer Sport The frame consists of two steel channel rails, a rear crossmember, additional support crossmembers and a front crossmember. The rails and crossmembers are not to be removed from the frame (5005) for repair except for the spare tire carrier plate. A front frame rail repair kit (5D058 and 5D059) is available if the front rail is to be repaired. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Body Support - Number 1 Body / Frame Mount Bushing: Service and Repair Body Support - Number 1 BODY SUPPORT - NUMBER 1 Materials Materials Removal and Installation NOTE: Left side shown, right side similar. Upper and Lower Insulator 1. Remove the door scuff plate. 2. Remove the A-pillar lower trim panel. 1. Remove the pin-type retainer. 2. Remove the A-pillar lower trim panel. 3. Position back the carpeting and remove the body insulator plug. 4. NOTE: This step may require holding the lower retainer with an appropriate tool. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Body Support - Number 1 > Page 8953 Remove the body mount insulator bolt. 5. NOTE: If the lower body mount will not remove, loosely install the body mount bolt and tap on the body mount bolt head with a hammer. Remove the lower body mount insulator. Upper Insulator 6. Loosen, but do not remove, all the remaining body mount insulator bolts. 7. Carefully raise the vehicle body enough to remove the upper body mount insulator. Upper and Lower Insulator 8. NOTE: - Apply Threadlock 262 E2FZ-19554-B meeting Ford specification WSK-M2G351-A6 or equivalent to the mounting bolt. - No lubricants of any kind are to be used during body insulator installation. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Body Support - Number 1 > Page 8954 Body / Frame Mount Bushing: Service and Repair Body Support - Number 2 BODY SUPPORT - NUMBER 2 Materials Materials Removal and Installation NOTE: Left side shown, right side similar. Upper and Lower Insulator 1. Position the front seat forward. 2. Remove the door scuff plates. 3. Position back the carpeting and remove the body insulator plug. 4. NOTE: This step may require holding the lower retainer with an appropriate tool. Remove the body mount insulator bolt. 5. NOTE: If the lower body mount will not remove, loosely install the body mount bolt and tap on the body mount bolt head with a hammer. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Body Support - Number 1 > Page 8955 Remove the lower body mount insulator. Upper Insulator 6. Loosen, but do not remove, all the remaining body mount insulator bolts. 7. Carefully raise the vehicle body enough to remove the upper body mount insulator. Upper and Lower Insulator 8. NOTE: - Apply Threadlock 262 E2FZ-19554-B meeting Ford specification WSK-M2G351-A6 or equivalent to the mounting bolt. - No lubricants of any kind are to be used during body insulator installation. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Body Support - Number 1 > Page 8956 Body / Frame Mount Bushing: Service and Repair Body Support - Number 3 BODY SUPPORT - NUMBER 3 Materials Materials Removal and Installation NOTE: Left side shown, right side similar. Upper and Lower Insulator - All Vehicles 1. Fold the rear seat forward. Upper and Lower Insulator - Explorer Sport 2. Position the carpet aside. Upper and Lower Insulator - Sport Trac 3. Open the storage compartment. Upper and Lower Insulator - All Vehicles 4. Remove the body insulator plug 5. NOTE: This step may require holding the lower retainer with an appropriate tool. Remove the body mount insulator bolt. Lower Insulator - All Vehicles Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Body Support - Number 1 > Page 8957 6. NOTE: If the lower body mount will not remove, loosely install the body mount bolt and tap on the body mount bolt head with a hammer. Remove the lower body mount insulator. Upper Insulator - All Vehicles 7. Carefully raise the vehicle body enough to remove the upper body mount insulator. Upper and Lower Insulator - All Vehicles 8. NOTE: - Apply Threadlock 262 E2FZ-19554-B meeting Ford specification WSK-M2G351-A6 or equivalent to the mounting bolt. - No lubricants of any kind are to be used during body insulator installation. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Body Support - Number 1 > Page 8958 Body / Frame Mount Bushing: Service and Repair Body Support - Number 4 BODY SUPPORT- NUMBER 4 Materials Materials Removal and Installation NOTE: Left side shown, right side similar. Upper and Lower Insulator 1. Remove the liftgate scuff plate. 1. Release the locking tabs. 2. Remove the scuff plate. 2. NOTE: This step may require holding the lower retainer with an appropriate tool. Position back the carpeting and remove the body mount insulator bolt. 3. NOTE: If the lower body mount will not remove, loosely install the body mount bolt and tap on the body mount bolt head with a hammer. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Body Support - Number 1 > Page 8959 Remove the lower body mount insulator. Upper Insulator 4. Loosen, but do not remove, all the remaining body mount insulator bolts. 5. Carefully raise the vehicle body enough to remove the upper body mount insulator. Upper and Lower Insulator 6. NOTE: - Apply Threadlock 262 E2FZ-19554-B meeting Ford specification WSK-M2G351-A6 or equivalent to the mounting bolt. - No lubricants of any kind are to be used during body insulator installation. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Body Support - Number 1 > Page 8960 Body / Frame Mount Bushing: Service and Repair Body Support - Radiator Support BODY SUPPORT - RADIATOR SUPPORT Removal and Installation NOTE: Left side shown, right side similar. Upper and Lower Insulator 1. From inside the engine compartment, remove the body mount insulator nut and backing plate and discard the nut. Lower Insulator 2. Remove the lower radiator body mount. 1. Remove the lower body mount bolt and discard. 2. Remove the lower body mount. Upper and Lower Insulator 3. Carefully raise the vehicle body enough to remove the upper radiator body mount insulator. 4. NOTE: - Do not reuse body support mounting fasteners. New fasteners must be installed for each fastener that has been removed or loosened. - No lubricants of any kind are to be used during body insulator installation. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Specifications Front Cross-Member: Specifications Automatic Crossmember screws .......................................................................................................................... ...................................... 85-118 Nm (63-87 ft. lbs.) Crossmember nuts ............................................. ....................................................................................................................... 88-115 Nm (65-85 ft. lbs.) Manual Crossmember bolts ............................................................................................................................. ........................................ 53-72 Nm (39-53 ft. lbs.) Crossmember nuts ............................................. ......................................................................................................................... 53-72 Nm (39-53 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information > Service and Repair Rear Cross-Member: Service and Repair CROSSMEMBER - TRANSMISSION SUPPORT Materials Materials Removal and Installation 1. Raise and support the vehicle. 2. Loosen, but do not remove, the nuts retaining the transmission insulator to the crossmember. 3. Support the transmission. 4. Remove the six bolts retaining the crossmember to the frame. 5. Remove the nuts and the crossmember. 6. NOTE: Apply Threadlock 262 E2FZ-19554-B meeting Ford specification WSK-M2G351-A6 or equivalent to the transmission crossmember mounting bolts. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Customer Interest for Trailer Hitch: > 01-11-10 > Jun > 01 > Trailer Hitch - Insufficient Receiver Clearance Trailer Hitch: Customer Interest Trailer Hitch - Insufficient Receiver Clearance Article No. 01-11-10 06/11/01 BODY - FRAME - INSUFFICIENT CLEARANCE IN THE TRAILER HITCH RECEIVER FORD: 2002 EXPLORER MERCURY: 2002 MOUNTAINEER ISSUE Some 2002 Explorer/Mountaineer vehicles equipped with a Class II hitch may exhibit insufficient clearance in the receiver to attach tubular hitch accessories to the vehicle. This may be due to excessive powder coat and e-coat build-up inside the receiver. ACTION To correct this condition, perform the following Service Procedure to remove the excessive paint build-up inside the receiver. SERVICE PROCEDURE CAUTION MAKE SURE TO WEAR PROPER EYE PROTECTION DURING THIS PROCEDURE. 1. Take a 19 mm (3/4") diameter wire brush and attach it to a regular power drill. Insert the wire brush into the receiver tube and remove the black coating on all the sides. 2. Take a 32 mm (1-1/4") flat file and make several passes on the four sides (inside) of the receiver tube until bare metal is visible to the eye. 3. Clean out the coatings and metal dust using an air hose and a piece of cloth. 4. Spray Rustoleum - Gloss Black Spray (obtain locally) inside the receiver tube covering the exposed bare metal inside surface with a thin coat. 5. Inspect the inside of the hitch to make sure that all of the surfaces are covered by the spray paint. 6. Allow paint to dry. 7. Verify repair. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011110A Remove Excessive Paint 0.3 Hr. Build-Up Inside Receiver (Includes Time To Mask Bumper Before Painting Receiver) DEALER CODING CONDITION BASIC PART NO. CODE Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Customer Interest for Trailer Hitch: > 01-11-10 > Jun > 01 > Trailer Hitch - Insufficient Receiver Clearance > Page 8976 17D826 07 OASIS CODES: 106000, 108000, 205000, 305000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 01-11-10 > Jun > 01 > Trailer Hitch - Insufficient Receiver Clearance Trailer Hitch: All Technical Service Bulletins Trailer Hitch - Insufficient Receiver Clearance Article No. 01-11-10 06/11/01 BODY - FRAME - INSUFFICIENT CLEARANCE IN THE TRAILER HITCH RECEIVER FORD: 2002 EXPLORER MERCURY: 2002 MOUNTAINEER ISSUE Some 2002 Explorer/Mountaineer vehicles equipped with a Class II hitch may exhibit insufficient clearance in the receiver to attach tubular hitch accessories to the vehicle. This may be due to excessive powder coat and e-coat build-up inside the receiver. ACTION To correct this condition, perform the following Service Procedure to remove the excessive paint build-up inside the receiver. SERVICE PROCEDURE CAUTION MAKE SURE TO WEAR PROPER EYE PROTECTION DURING THIS PROCEDURE. 1. Take a 19 mm (3/4") diameter wire brush and attach it to a regular power drill. Insert the wire brush into the receiver tube and remove the black coating on all the sides. 2. Take a 32 mm (1-1/4") flat file and make several passes on the four sides (inside) of the receiver tube until bare metal is visible to the eye. 3. Clean out the coatings and metal dust using an air hose and a piece of cloth. 4. Spray Rustoleum - Gloss Black Spray (obtain locally) inside the receiver tube covering the exposed bare metal inside surface with a thin coat. 5. Inspect the inside of the hitch to make sure that all of the surfaces are covered by the spray paint. 6. Allow paint to dry. 7. Verify repair. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011110A Remove Excessive Paint 0.3 Hr. Build-Up Inside Receiver (Includes Time To Mask Bumper Before Painting Receiver) DEALER CODING CONDITION BASIC PART NO. CODE Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 01-11-10 > Jun > 01 > Trailer Hitch - Insufficient Receiver Clearance > Page 8982 17D826 07 OASIS CODES: 106000, 108000, 205000, 305000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair Grille: Service and Repair RADIATOR GRILLE Removal and Installation 1. Remove the front bumper cover. 2. Remove the radiator grilles. 1. Remove the four pin-type retainers. 2. Release the six clips. 3. Remove the radiator grilles. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Specifications Torque Specifications Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Specifications > Page 8990 Connector View C930 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Description and Operation > Overhead and Floor Console Console: Description and Operation Overhead and Floor Console Console - Overhead The overhead console consists of the following components: compass/thermometer display - garage door opener storage (without roof opening panel) - map/courtesy lamps - map/courtesy lamp switch - roof opening panel control switch (with roof opening panel) Console - Floor The high series floor console consists of the following components: armrest - ash cup - bin mat - console finish panel - coin holder - power point - cup holder insert - storage compartment - rear cup holders - rear integrated control panel The base floor console consists of the following components: arm rest - carry bag - front cup holders - rear cup holders If the vehicle is equipped with manual transmission, there will be a consolette at the base of the gearshift lever. The consolette contains two cup holders, covers the Restraint Control Module (RCM) and is attached by two screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Description and Operation > Overhead and Floor Console > Page 8993 Console: Description and Operation Flow-Thru Floor Console Vehicles equipped with the high series flow-thru floor console have a ventilation system for second row passengers. The high series flow-thru floor console has the following features: - The center console is supplied with air from the plenum chamber through an auxiliary duct to the second row blower motor. - The second row blower motor, mounted in the center console, increases the air flow to the auxiliary floor duct and registers. - A mechanically actuated air management door controls airflow to either the auxiliary registers or the auxiliary floor vent. - The blower switch and air management door control switch are located in the second row climate control assembly, located in the rear of the center console. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Floor Console Console: Service and Repair Floor Console High Series REMOVAL 1. Disconnect the battery ground cable. 2. Remove the floor console tray. Lift upward at the rear first. 3. Disconnect the floor console electrical connectors. 4. Remove the floor console front bolts. 5. Remove the floor console center bolts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Floor Console > Page 8996 6. Remove the floor console. NOTE: The console must be moved rearward to disengage the rear mounting bracket. INSTALLATION 1. To install, reverse the removal procedure. Base Series REMOVAL 1. Remove the front seat center armrest. 1 Remove the two covers. 2 Remove the four bolts. 3 Remove the armrest. 2. Remove the utility tray beverage holder. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Floor Console > Page 8997 3. Remove the floor console. 1 Remove the screws. 2 Remove the floor console. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Floor Console > Page 8998 Console: Service and Repair Overhead Console REMOVAL 1. Disconnect the battery ground cable. 2. If equipped, open the garage door remote cover. 3. If equipped, remove the screws. 4. Remove the overhead console. NOTE: On vehicles equipped with a roof opening panel the overhead console is a snap-fit. 5. Disconnect the electrical connector (two connectors on vehicles equipped with a roof opening panel). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Floor Console > Page 8999 INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Customer Safety Information Air Bag(s) Arming and Disarming: Customer Safety Information WARNING: ^ IF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS BEING SERVICED, THE SYSTEM MUST BE DEACTIVATED AND RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED. ^ THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, TURN THE IGNITION OFF AND DISCONNECT THE BATTERY GROUND CABLE, WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Customer Safety Information > Page 9005 Air Bag(s) Arming and Disarming: Technician Safety Information WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, CAUTIONS, AND NOTES AT THE BEGINNING OF THE DEACTIVATION PROCEDURE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Customer Safety Information > Page 9006 Air Bag(s) Arming and Disarming: Vehicle Damage Warnings CAUTION: ^ Do not handle the passenger air bag module by grabbing the edges of the deployment door. ^ Do not deactivate the side air bag module circuit be removing the side air bag bridge resistor from the side air bag to floor connector. ^ If the side air bag bridge resistor is removed, an open circuit fault will be generated by the Restraints Control Module (RCM). ^ If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Deactivation Procedure Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will This will reduce the risk of injury in the event of an accidental deployment. WARNING: To reduce the risk of personal injury, do not use any memory saver devices. NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood connected. WARNING: To reduce the risk of personal injury, do not use any memory saver devices. NOTE: The air bag warning lamp illuminates when the RGM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9009 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, See: Starting and Charging/Battery 7. Remove the two steering wheel back cover plugs. 8. Remove the driver air bag module retaining bolts. 9. Remove the driver air bag module. 1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9010 10. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector at the top of the steering column. 11. Open the glove compartment door past its stops to access the mounting screws. 12. Remove the two screws. 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Reaching one hand into the glove compartment opening push out on the passenger air bag module and separate it from the instrument panel. Note the wire harness routing for installation. 14. Disconnect the electrical connector and remove the passenger air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9011 15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. Vehicles without seat side air bags 16. CAUTION: Do not deactivate the side air bag module circuit be removing the side air bag bridge resistor from the side air bag to floor connector. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM). If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. Vehicles with seat side air bags and power driver seat 17. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. For additional information, See: Starting and Charging/Battery Vehicles with seat side air bags 18. Move and tilt the front seats to their highest and most forward position. Vehicles with seat side air bags and power driver seat 19. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, See: Starting and Charging/Battery Vehicles with seat side air bags 20. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector. 21. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9012 22. Remove the tie-strap and disconnect the driver seat side air bag electrical connector. 23. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. All vehicles 24. Install the RCM fuse F2.6 (7.5A without rear blower, 15A with rear blower) to the CJB and close the cover. 25. Connect the battery ground cable. For additional See: Starting and Charging/Battery Reactivation Procedure Reactivation All vehicles 1. Turn the ignition switch to OFF. 2. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For additional information, refer to the wiring Diagram Manual. 3. Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, See: Starting and Charging/Battery Vehicles with seat side air bags 4. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9013 5. Connect the driver seat side air bag electrical connector and tie-strap the wire harness. 6. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical connector. 7. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. Vehicles with seat side air bags and power driver seat 8. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. For additional information, See: Starting and Charging/Battery Vehicles with seat side air bags 9. Position the front seats rearward. Vehicles with seat side air bags and power driver seat 10. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, refer to See: Starting and Charging/Battery All vehicles Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9014 11. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. 12. Position the passenger air bag module to the instrument panel (I/P) and connect the electrical connector. 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Position the passenger air bag module into the instrument panel. Route the wire harness as noted in removal. 14. Install the two screws. 15. Close the glove compartment door. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9015 16. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector at the top of the steering column. 17. Position the driver air bag module to the steering wheel. 1. Connect the driver air bag module electrical connector. 2. Position the driver air bag module to the steering wheel. 18. Install the two driver air bag module retaining bolts. 19. Install the two steering wheel back cover plugs. 20. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 21. Turn the ignition switch from OFF to ON. 22. Install the RCM fuse F2.6 (7.5A without rear blower, 15A with rear blower) to the CJB and close the cover. 23. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9016 Connect the battery ground cable. 24. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: -fail to light. -remain lit continuously. -flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. 25. Clear all continuous DTCs from the restraints control module using a scan tool. Seats Removed There are two deactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. WARNING: IF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS BEING SERVICED, THE SYSTEM MUST BE DEACTIVATED AND RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED. THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. NOTE: ^ Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Disconnect the battery ground cable. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the driver air bag module. 4. Attach a Restraint System Diagnostic Tool 418-F088 (105-R0012) to the clockspring side of the driver air bag module connector. 5. Remove the passenger air bag module. 6. Attach a Restraint System Diagnostic Tool 418-F088 (105-R0012) to the vehicle harness side of the passenger air bag connector. 7. If equipped with a front power driver seat, reconnect the battery ground cable. 8. Move and tilt the front seats to their highest and most forward position. 9. If equipped with a front power driver seat, disconnect the battery ground cable. 10. Remove the affected front seat(s). 11. Disconnect the passenger seat side air bag module electrical connector (if necessary) and attach Restraint System Diagnostic Tool 418-133 (40-009) to the vehicle harness side of the passenger seat side air bag module electrical connector. 12. Disconnect the driver seat side air bag module electrical connector (if necessary) and attach Restraint System Diagnostic Tool 418-133 (40-009) to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9017 the vehicle harness side of the driver seat side air bag module electrical connector. 13. Reconnect the battery ground cable. Seats Not Removed There are two deactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. WARNING: IF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS BEING SERVICED, THE SYSTEM MUST BE DEACTIVATED AND RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED. THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. NOTE: ^ Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Disconnect the battery ground cable. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the driver air bag module. 4. Attach a Restraint System Diagnostic Tool 418-F088 (105-R0012) to the clockspring side of the driver air bag module connector. 5. Remove the passenger air bag module. 6. Attach a Restraint System Diagnostic Tool 418-F088 (105-R0012) to the vehicle harness side of the passenger air bag connector. 7. If equipped with seat side air bags and a front power driver seat reconnect the battery ground cable. 8. Move and tilt the front seats to their highest and most forward position. 9. If equipped with seat side air bags and a front power driver seat, disconnect the battery ground cable. 10. If equipped with seat side air bags, disconnect the passenger seat side air bag module electrical connector and attach Restraint System Diagnostic Tool 418-133 (40-009) to the vehicle harness side of the passenger seat side air bag module electrical connector. CAUTION: Vehicles without side air bags, do not deactivate the side air bag module circuit by removing the side air bag bridge resistor from the side air bag floor connector. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM). If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. 11. If equipped with seat side air bags, disconnect the driver seat side air bag module electrical connector and attach Restraint System Diagnostic Tool 418-133 (40-009) to the vehicle harness side of the driver seat side air bag module electrical connector. CAUTION: Vehicles without side air bags, do not deactivate the side air bag module circuit by removing the side air bag bridge resistor from the side air bag floor connector. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9018 If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. 12. Reconnect the battery ground cable. Seats Removed There are two reactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES AND PRETENSIONERS MUST BE RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. 1. Move and tilt the front seats to their highest and most forward position. 2. Disconnect the battery ground cable. 3. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 4. Remove the restraint system diagnostic tool from the driver seat side air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. Remove the restraint system diagnostic tool from the passenger seat side air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 6. Install the affected front seat(s). 7. Connect the driver seat side air bag module electrical connectors. 8. Connect the passenger seat side air bag module electrical connectors. 9. If equipped with a front power driver seat, reconnect the battery ground cable. 10. Move the front seats rearward. 11. If equipped with a front power driver seat, disconnect the battery ground cable. 12. Remove the restraint system diagnostic tool from the passenger air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 13. Install the passenger air bag module. 14. Remove the restraint system diagnostic tool from the clockspring connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 15. Install the driver air bag module. 16. Reconnect the battery ground cable. 17. Prove out the system. Seats Not Removed There are two reactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES AND Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9019 PRETENSIONERS MUST BE RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. 1. If equipped with seat side air bags, move and tilt the front seats to their highest and most forward position. 2. Disconnect the battery ground cable. 3. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 4. If equipped with seat side air bags: 1 Remove the restraint system diagnostic tool from the driver seat side air bag module electrical connector. 2 Remove the restraint system diagnostic tool from the passenger seat side air bag module electrical connector. 3 Connect the driver seat side air bag module electrical connectors. 4 Connect the passenger seat side air bag module electrical connectors. 5 Reconnect the battery ground cable. 6 Move the front seats rearward. 7 Disconnect the battery ground cable. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. Remove the restraint system diagnostic tool from the passenger air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 6. Install the passenger air bag module. 7. Remove the restraint system diagnostic tool from the clockspring connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 8. Install the driver air bag module. 9. Reconnect the battery ground cable. 10. Prove out the system. Procedures For Repair Operations SPECIAL TOOL(S) DEACTIVATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9020 INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the air bag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the seat side air bag (if equipped) and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Remove the retaining screws and position the hood release handle out of the way. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9021 3. Remove the lower steering column opening finish panel. 1 Remove the two retaining screws from the lower steering column opening finish panel. 2 Pull out to release the retaining clips and remove the lower steering column opening finish panel. 4. Remove the bolts and the lower steering column opening finish panel reinforcement. 5. Disconnect the clockspring electrical connector at the base of the steering column. 6. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9022 7. Open the glove compartment door past its stops to access the mounting screws. 8. Remove the two screws. 9. Reaching one hand into the glove compartment opening, push out on the passenger air bag module and separate it from the instrument panel. Note the wire harness routing for installation. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. 10. Disconnect the electrical connector and remove the passenger air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9023 11. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. Vehicles without seat side air bags 12. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the Restraints Control Module (RCM). If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. CAUTION: Do not deactivate the side air bag module circuit be removing the side air bag bridge resistor from the side air bag to floor connector. Vehicles with seat side air bags and power driver seat 13. Connect the battery ground cable. Vehicles with seat side air bags 14. Move and tilt the front seats to their highest and most forward position. Vehicles with seat side air bags and power driver seat 15. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Vehicles with seat side air bags 16. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9024 17. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. 18. Remove the tie-strap and disconnect the driver seat side air bag electrical connector. 19. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. All vehicles 20. Connect the battery ground cable. 21. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). See: Prove Out Procedure 22. Disconnect the battery ground cable and wait at least one minute. REACTIVATION WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, CAUTIONS, AND NOTES AT THE BEGINNING OF THE DEACTIVATION PROCEDURE. Vehicles with seat side air bags Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9025 1. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical connector. NOTE: Make sure the battery ground cable is still disconnected before proceeding with the reactivation portion of this procedure. 2. Connect the driver seat side air bag electrical connector and tie-strap the wire harness. 3. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical connector. 4. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. Vehicles with seat side air bags and power driver seat 5. Connect the battery ground cable. Vehicles with seat side air bags 6. Position the front seats rearward. Vehicles with seat side air bags and power driver seat Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9026 7. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). All vehicles 8. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. 9. Position the passenger air bag module to the Instrument Panel (I/P) and connect the electrical connector. 10. Position the passenger air bag module into the instrument panel. Route the wire harness as noted in removal. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9027 11. In stall the two screws. 12. Close the glove compartment door. 13. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector at the base of the steering column. 14. Connect the clockspring electrical connector at the base of the steering column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9028 15. Position the lower steering column opening finish panel reinforcement and install the bolts. 16. Install the lower steering column opening finish panel. 1 Position the lower steering column opening finish panel to the I/P and push in at the top to seat the retaining clips. 2 Install the screws. 17. Position the hood release handle and install the screws. 18. Connect the battery ground cable. 19. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Prove Out Procedure WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 20. Check the active restraint system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9029 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag modules connected? 3. Is the Restraints Control Module (RCM) connected? 4. Is the vehicle battery connected? Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9030 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure Turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator with the air bag modules or restraint system diagnostic tools installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag Supplemental Restraint System (SRS) fault is present, the air bag indicator will either: ^ fail to light. ^ remain lit continuously. ^ flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the RUN position. This is the time required for the Restraints Control Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Page 9031 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair Headliner: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the C-pillar trim panel. 3. Remove the overhead console. 4. Remove the interior lamp lens. 5. Remove the screws and the interior lamp. 6. Remove the two sun visors. 1 Remove the six screws. 2 Remove the two sun visors. - If equipped, disconnect the electrical connectors. 7. Remove the two sun visor brackets. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 9035 1 Remove the two screws. 2 Remove the two sun visor brackets. 8. Remove the six assist handle bolt covers. 9. Remove the three assist handles. 1 Remove the six bolts. 2 Remove the three assist handles. 10. Remove the passenger seat. NOTE: The headliner is removed through the passenger side front door. 11. Remove the headliner. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > B-Pillar Trim Panel Trim Panel: Service and Repair B-Pillar Trim Panel Safety Belt Bolt Bit SPECIAL TOOL(S) REMOVAL 1. Remove the windshield side garnish moulding. 2. Remove the scuff plate. 1 Starting at one end and working along the scuff plate, release the scuff plate locking tabs. 2 Remove the scuff plate. 3. Remove the coat hook. 1 Remove the screw. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > B-Pillar Trim Panel > Page 9040 2 Remove the coat hook. 4. From behind the front shoulder safety belt guide cover, release the retaining tab and open the cover. NOTE: Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is damaged or if it does not remain closed, install a new shoulder safety belt guide cover. - Shoulder safety belt guide cover shown removed for clarity. 5. Remove the nut and shoulder safety belt guide. 6. Position the carpet aside. 7. Using the special tool, remove the front safety belt anchor bolt. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > B-Pillar Trim Panel > Page 9041 8. Remove the B-pillar trim panel. 1 Remove the pin-type retainer. 2 Feed the safety belt webbing through the opening. 3 Remove the B-pillar trim panel. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > B-Pillar Trim Panel > Page 9042 Trim Panel: Service and Repair C-Pillar Trim Panel Safety Belt Bolt Bit SPECIAL TOOL(S) REMOVAL 1. Remove the B-pillar trim panel. 2. Fold down the rear seat. 3. From behind the front shoulder safety belt guide cover, release the retaining tab and open the cover. NOTE: Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide cover is damaged or if it does not remain closed, install a new shoulder safety belt guide cover. - Shoulder safety belt guide cover shown removed for clarity. 4. Remove the nut and shoulder safety belt guide. 5. Position the carpet aside. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > B-Pillar Trim Panel > Page 9043 6. Remove the safety belt anchor trim cover. 7. Remove the rear safety belt anchor nut. 8. Remove the roof trim panel. 9. Remove the six luggage compartment back lower trim cover screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > B-Pillar Trim Panel > Page 9044 10. Remove the luggage compartment back lower trim cover. - Remove the six pin-type retainers. 11. Remove the pin-type retainer from C-pillar trim panel. 12. Remove the safety belt anchor trim cover. 13. Remove the C-pillar trim panel. - Feed the safety belt webbing through the opening. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > B-Pillar Trim Panel > Page 9045 Trim Panel: Service and Repair Rear Door Trim Panel REMOVAL High Series Door Trim Panels 1. Remove the rear door window control switch panel. - Disconnect the electrical connector. All Door Trim Panels 2. Remove the door handle cup screws. 3. Remove the door handle cup. Low Series Door Trim Panels 4. Remove the screw and the window regulator handle. All Door Trim Panels Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > B-Pillar Trim Panel > Page 9046 5. Remove the rear door trim panel. 1 Remove the screw. 2 Remove the rear door trim panel. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Page 9047 Seat Belt Bolt Bit Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair Door Lock Cylinder: Service and Repair REMOVAL NOTE: - When a new lock cylinder is installed, both door lock cylinders, liftgate lock cylinders, tailgate and ignition lock cylinder should be installed as a set. This will eliminate carrying an extra key which will fit only one lock. If a new key is to be used, the new key code number is stamped on a metal tag attached to the key. - Individual lock cylinders are repaired by discarding the inoperative cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle. 1. Remove the front door trim panel. 2. Make sure the window is in the fully raised position. 3. Position the watershield aside. 4. Remove the door lock cylinder. 1 Disconnect the lock cylinder rod. 2 Remove the retaining clip. 3 Remove the door lock cylinder. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics Keyless Entry Key-Pad: Technical Service Bulletins Keyless Entry - Keypad Diagnostics TSB 06-15-8 08/07/06 KEYPAD DIAGNOSTICS - DEALER INSTALLED ACCESSORY FORD: 1998-2006 Taurus 1999-2003 Escort 1999-2006 Mustang 2000-2006 Focus 2002-2005 Thunderbird 2005-2006 Five Hundred, Freestyle 2006 Crown Victoria, Fusion 1998-2006 Expedition, Explorer, F-150, Ranger 1999 F-250 Light Duty 1999-2003 Windstar 1999-2006 F-Super Duty 2000-2005 Excursion 2000-2006 E-Series 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004 F-150 Heritage 2004-2006 Freestar LINCOLN: 1998-2006 Town Car 2000-2006 Lincoln LS 2006 Zephyr 1998-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006 Mark LT MERCURY: 1998-2005 Sable 1999-2002 Cougar 2005-2006 Montego 2006 Grand Marquis, Milan 1998-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner ISSUE Some vehicles may experience a concern with the keyless entry keypad. In order to properly diagnose the concern with the keyless entry keypad, it is important to identify whether the keypad is a factory installed style (wired) or a Genuine Ford Accessory (GFA) radio frequency (RF) style keypad. ACTION Use the following Service Procedure to identify GFA RF keypads and provide diagnostic service tips. SERVICE PROCEDURE IDENTIFICATION: 1. Production installed keyless entry keypads are mounted flush with the surface of the vehicle and are wired directly to the module controlling the vehicle's keyless entry system. This style keypad can be diagnosed using the appropriate Workshop Manual (WSM), Section 501-14. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 9058 2. Dealer installed GFA RF keypads are adhesive backed and protrude approximately 1/2" (13 mm) from the surface of the vehicle and there are no specific diagnostics available in the WSM (Figure 1). NOTE THIS RF KEYPAD WAS ALSO US[D IN PRODUCTION ON 2004 F-SUPER DUTY VEHICLES BUILT PRIOR TO 12/3/2003. REFER TO WSM, SECTION 501-14 FOR RF KEYPAD DIAGNOSTICS FOR THESE VEHICLES. GENUINE FORD ACCESSORY KEYPAD DIAGNOSTIC TIPS 1. The keypad operates similarly to a remote keyless entry (RKE) transmitter and is programmed using a similar procedure. Although the RF keypad is not specifically addressed in the WSM, the RKE transmitter programming portion of the WSM, Section 501-14 can be used as a guide NOTE THE 7-8 AND 9-0 BUTTONS ON THE KEYPAD MUST BE PRESSED SIMULTANEOUSLY DURING THE PROCEDURE IN ORDER FOR THE KEYPAD TO BE RECOGNIZED AS AN ADDITIONAL REMOTE TRANSMITTER. Since the GFA RF keypad is essentially another RKE transmitter, the transmitter diagnostic pinpoint tests in the vehicle's WSM can also be referenced even though the buttons serving the lock / unlock functions will differ 2. The GFA RF keypad is serviced as an assembly. The internal battery cannot be replaced separately. 3. If the master code or owner selectable code is lost or forgotten, the GFA RF keypad must be replaced. These codes are not stored in any vehicle module (with the exception of 2004 F-Super Duty vehicles produced prior to 12/3/2003). 4. The GFA RF keypad and all RKE transmitters (the number of transmitters allowable will vary by vehicle) must be reprogrammed together anytime the keypad is replaced, an RKE transmitter is replaced, or the module controlling the keyless entry system on the vehicle (GEM/SJB/VSM/DDM etc.) is replaced. NOTE THERE IS AN EXCEPTION TO TIP 4 FOR VEHICLES EQUIPPED WITH INTEGRATED KEYHEAD TRANSMITTERS (IKTs) (FUSION/MILAN/ZEPHYR). THE GFA RF KEYPADS FOR VEHICLES WITH IKTs MUST BE PROGRAMMED INDEPENDENTLY FROM THE IKTs. TURN THE IGNITION FROM "OFF" TO "RUN" 8 TIMES WITHIN 10 SECONDS, WITH THE 8TH TIME ENDING IN "RUN". THE DOOR LOCKS WILL CYCLE TO CONFIRM ENTERING PROGRAMMING MODE. PRESS THE 7-8 AND 9-0 BUTTON ON THE KEYPAD SIMULTANEOUSLY TO SEND A LOCK SIGNAL. TURN IGNITION TO OFF. THE LOCKS WILL CYCLE AGAIN TO INDICATE THE END OF THE PROGRAMMING MODE. 5. The keypad will normally illuminate for 5 seconds after one or more buttons are pressed, and the illumination will immediately turn off if the 7-8 and 9-0 buttons are pressed simultaneously (lock all doors). The keypad contains an optical sensor and will not illuminate under bright lighting conditions. The keypad may only illuminate briefly in colder temperatures in order to maximize the battery power available to transmit a lock/unlock signal. The temperature at which this occurs will vary depending upon the keypad battery age and condition. Both of these conditions are a normal function of the Power Save Mode and do not indicate a need to replace the keypad. 6. After entering the keypad code, the system may unlock the driver's door, lock it, then unlock it again, and the keypad will not even briefly illuminate. This is the Alert Mode and is an indication that battery power is very low and the keypad must be replaced. 7. The keypad also contains an Anti-scan feature. If the wrong code has been entered 7 times (35 consecutive button presses) the keypad is disabled for one minute and the keypad lamp will flash during this time. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 9059 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 14A626 42 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Page 9060 Connector View C530 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Page 9061 Keyless Entry Key-Pad: Service and Repair REMOVAL 1. Remove the front door speaker. 2. Disconnect the keyless entry electrical connector. 3. Remove the two wiring harness locators. 4. Release the retaining clip. 5. Remove the keyless entry keypad. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Application and ID Keyless Entry Module: Application and ID For further information please see Accessories and Optional Equipment, General Module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Driver Side Connector View C525 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Driver Side > Page 9070 Connector View C704 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Driver Side > Page 9071 Connector View C804 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Driver Side > Page 9072 Connector View C603 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Page 9073 Power Door Lock Actuator: Service and Repair Heavy Duty Riveter SPECIAL TOOL(S) REMOVAL 1. Remove the front door trim panel. 2. Position the watershield aside. 3. Remove the door glass run channel. 1 Remove the bolt. 2 Remove the door glass run channel. Release the wiring harness locator. 4. Disconnect the door lock actuator electrical connector. 5. Remove the front door lock actuator rivet. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Page 9074 6. Release the wiring harness locator. 7. Remove the front door lock actuator. INSTALLATION 1. To install, reverse the removal procedure. - Using the special tool, install the rivet. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Page 9075 Heavy Duty Riveter Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Application and ID Power Door Lock Control Module: Application and ID For further information please see Accessories and Optional Equipment, General Module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Driver Side Connector View C505 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Driver Side > Page 9083 Connector View C605 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Driver Side Power Door Lock Switch: Testing and Inspection Driver Side Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Driver Side > Page 9086 Door Lock Switch, Driver Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Driver Side > Page 9087 Power Door Lock Switch: Testing and Inspection Passenger Side Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Driver Side > Page 9088 Door Lock Switch, Passenger Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Service and Repair Trunk / Liftgate Lock Cylinder: Service and Repair REMOVAL NOTE: Individual lock cylinders are repaired by discarding the inoperative cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle; 1. Remove the liftgate latch remote control. 2. Remove the liftgate lock cylinder. 1 Remove the nuts. 2 Remove the liftgate lock cylinder. If equipped, disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Service and Repair Power Mirror Motor: Service and Repair REMOVAL NOTE: - The exterior mirror motor is serviceable only on vehicles built after July of 2001. - Passenger side exterior mirror shown, driver side exterior mirror similar. 1. Remove the exterior mirror glass. 2. Position aside the exterior mirror motor. 1 Remove the screws. 2 Position aside the exterior mirror motor. 3. Disconnect the electrical connectors and remove the exterior mirror motor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams Connector View C527 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams > Page 9099 Power Mirror Switch: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams > Page 9100 Exterior Rear View Mirror Switch Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams > Page 9101 Exterior Rear View Mirror Switch Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Plastic Bumper/Fascia Service Tips Paint: Technical Service Bulletins Paint - Plastic Bumper/Fascia Service Tips Article No. 03-10-1 PAINT - PLASTIC BUMPER/FASCIA PARTS - PREPARATION PROCEDURES - SERVICE TIPS FORD: 2002-2003 CROWN VICTORIA, FOCUS, MUSTANG, TAURUS, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, EXPLORER, WINDSTAR LINCOLN: 2002 CONTINENTAL 2002-2003 LS, TOWN CAR, NAVIGATOR MERCURY: 2002-2003 COUGAR, GRAND MARQUIS, SABLE 2002 VILLAGER 2002-2003 MOUNTAINEER ISSUE This article is being written to clarify the proper procedures to prepare plastic fascia parts. Multiple repair procedures for painting plastic fascia parts are being used in the field that are inconsistent and may not provide adequate paint adhesion. Paint companies repair procedures are system specific and do not lend themselves to generic repair procedures. ACTION Follow the repair information in this TSB flow chart to perform the initial steps for fascia paint repair only. After completing the flow chart refer to paint company system recommendations for materials and mixing instructions for the type of plastic being painted. Also listed in this TSB are some important service tips to remember when preparing plastic parts for paint application. SERVICE INFORMATION For repair information, refer to flow chart Figure 1. Additional Service Tips: - When washing plastic parts use Motorcraft Detail Wash (ZC-3-A) mixed at a ratio (1 oz. of ZC-3-A) to 1 gallon of water. - Use basecoat reducer for a wipe test on coated service parts. - If the coating (adhesion promoter/primer) shrivels or lifts, remove only that layer of material by Scotchbrite scuffing or machine sanding. Never remove material to bare plastic substrate, as this will create more work in order to protect the substrate for application of paint. - If the adhesion promoter or primer is intact, use a gray Scotchbrite pad and scuff the entire part to continue preparation steps for normal paint application. - Follow paint company recommendations for primer or basecoat application. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Plastic Bumper/Fascia Service Tips > Page 9107 Paint: Technical Service Bulletins Paint - Premature Clearcoat Cracking Service Tips Article No. 02-17-1 PAINT-PREMATURE CLEARCOAT CRACKING-SERVICE TIPS FORD: 1999-2002 EXPLORER 2000-2002 EXPLORER SPORT TRAC, EXPLORER SPORT MERCURY: 1999-2002 MOUNTAINEER ISSUE Some vehicles may exhibit crowsfoot or premature star cracking primarily on the hood, but could also be on other panels. This is due to high paint film build and acrylic melamine paint technology. ACTION Read this TSB in its entirety BEFORE beginning any repairs. Inspect and repair as outlined in following Service Procedures. SERVICE PROCEDURE 1999-2002 Vehicles-Dark Colors (Code LL Blue, Code UA Black, and Code SU Green only) NOTE READ THIS REPAIR PROCEDURE COMPLETELY. SUBJECT VEHICLES HAVE PAINT THICKNESS ABOVE 5.5 MILS. 1. Check paint film thickness on affected panels. NOTE IF PLASTIC MEDIA BLASTING IS BEING USED, PROCEED TO STEP 4. NOTE TECHNICIAN PERFORMING THE SANDING OPERATION SHOULD WEAR AN APPROVED RESPIRATOR WITH HIGH EFFICIENCY PARTICULATE FILTERS (HEPA). TECHNICIANS SHOULD USE A DUAL ACTION SANDER WITH VACUUM COLLECTION EQUIPMENT. THE VACUUM EQUIPMENT MUST BE EQUIPPED WITH A HEPA FILTER ON THE AIR EXHAUST. OPERATORS ARE CAUTIONED TO FOLLOW MANUFACTURERS GUIDELINES FOR MAINTENANCE OR REPLACEMENT OF THESE FILTERS. 2. Remove all clearcoat and basecoat by sanding down to the E-coat primer with 80 grit-sanding discs on a Dual Action vacuum sander. The E-coat color is Green. 3. Blow off the panel with compressed air to remove loose dust and debris. 4. Wipe the panel with a wax and grease remover. Wipe dry using a clean, lint-free cloth to remove all residue. Keep wiping until the surface is completely dry. 5. Mask off all necessary panels. Tack off the surface. 6. Mix and apply Ford Approved epoxy or self-etching primer to all bare metal areas on the panel. 7. Mix and apply 2.0 mils minimum of Ford Approved primer surfacer following the manufacturers label recommendations and bake at 140°F (60° C) panel temperature per manufacturers recommended baking time. 8. Block sand the affected panels with 600 grit sand paper. 9. Blow off the area with compressed air to remove loose dust and debris. 10. Wipe the panel with a wax and grease remover. Wipe dry using a clean, lint-free cloth to remove all residue. NOTE KEEP WIPING UNTIL THE SURFACE IS COMPLETELY DRY. ANY RESIDUE MAY RESULT CONTAMINATION OF THE COATINGS TO BE APPLIED FOLLOWING THIS STEP. 11. Mix and apply Ford Approved basecoat material following the manufacturers label recommendations and flash time. 12. Mix and apply 2.0 mils minimum of Ford Approved clearcoat and bake at 140°F (60°C) panel temperature per manufacturers recommended baking time. 13. Demask the vehicle as necessary. WARNING TO SAFEGUARD OUR ENVIRONMENT, PLEASE USE PROPER DISPOSAL TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (VOC) OR EXCESS MATERIALS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Plastic Bumper/Fascia Service Tips > Page 9108 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Plastic Bumper/Fascia Service Tips > Page 9109 Paint: Technical Service Bulletins Paint - New Polishing Products and Procedures Article No. 02-16-3 PAINT-NEW POLISHING PRODUCTS-SERVICE PROCEDURES FORD: 2002-2003 CROWN VICTORIA, ESCORT, FOCUS, TAURUS, ESCAPE, EXCURSION, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, EXPLORER, F-150, RANGER, SUPER DUTY F SERIES, F-650, F-750 LINCOLN: 2002-2003 LS, TOWN CAR, NAVIGATOR MERCURY: 2002-2003 GRAND MARQUIS, SABLE, MOUNTAINEER ISSUE Vehicles that have small scratches, mars, dirt, and scuff marks found during pre-delivery or reconditioning may be repaired without repainting using new Motorcraft polishing products. These products may also be used effectively for collision damage repairs. ACTION Read this TSB in its entirety BEFORE beginning any repairs. Repair as outlined in the following Service Procedures. BACKGROUND The OEM paint system has changed significantly the last 18 months. Previous paint systems required a number days to be fully cured. The OEM paint system used today cures faster and is also much harder. The hardness of the OEM system is similar to the hardness of current Refinish paint system and as a result, a new polishing system is necessary. These products have been tested on all Ford Motor Company OEM paint finishes and all Major Refinish paint brands. The system has significantly better results than all other products tested for OEM and Refinish paint systems. NOTE THE USE OF FORD OR MOTORCRAFT BRAND PRODUCTS IS MANDATORY ON ALL REPAIR CLAIMS PAID BY FORD UNLESS OTHERWISE SPECIFIED IN EMISSIONS, FIELD SERVICE ACTIONS, CUSTOMER SATISFACTION PROGRAMS, TSB'S OR OTHER COMPANY PUBLICATIONS. THE COST OF NON-FORD/MOTORCRAFT PRODUCTS USED FOR A WARRANTY OR ESP/ESC, OR AWA REPAIR WITHOUT JUSTIFYING THEIR USE, (I.E., EMERGENCY REPAIR) IS NOT REIMBURSABLE. EXAMPLES OF FORD PRODUCTS ARE: ADHESIVES, SEALERS, SOLVENTS, CLEANERS, WASHES, AND OTHER SPECIAL PRODUCTS LISTED IN THE FORD CAR CARE PRODUCTS MANUAL. SERVICE PROCEDURE 1. Make sure the area to be polished is clean and free of paint sealants and waxes. 2. To remove dirt nibs, runs, or sags, sand the surface with a D.A. sander or by hand with P1500 grit sandpaper. 3. Apply the Motorcraft ZC-39-B backing pad to dual action sander. 4. Apply the Motorcraft polishing disc (ZC-39-A kit) to the D.A. sander. NOTE MAKE SURE THE POLISHING DISC IS CENTERED EXACTLY ON THE BACKING PAD, OR "WILD SCRATCHES" MAY OCCUR. 5. Dampen the polishing disc with water from a spray bottle before use. 6. Damp polish the repair area until the dirt, mar, etc. has been removed. The surface should now be semi-polished. NOTE IF THE IMPERFECTION CANNOT BE REMOVED WITH THE POLISHING DISC, HAND SAND WITH FINE SAND PAPER IN A STEP PROCESS (I.E. 600 GRIT, 1200 GRIT, 1500 GRIT). THE POLISHING DISC WILL ONLY REMOVE 1500 GRIT SCRATCHES AND HIGHER. 7. To remove the sand scratches and also remove swirl marks, install a foam-polishing pad onto a buffer. 8. Apply a small amount of the Motorcraft Finish Enhancement Compound on the foam pad for the first time of pad use. Do not use a wool pad with this product. 9. Move the pad around in a 2 foot area to spread out the material, then start up the buffer. Recommended speed is 1750 rpm. Apply medium pressure and let the polisher do the work. Verify the imperfection has been removed. If not, repeat Step 9 until complete. 10. Wipe the repair area with a detailing cloth to complete the repair. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Plastic Bumper/Fascia Service Tips > Page 9110 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes Paint: Application and ID Paint Codes The VC label is located on the left-hand front door edge. The first set of numbers/letters listed indicate the vehicle primary body color code. The second set of letters/numbers listed (if applicable), indicate a two-tone or accent body color code. Primary body color codes ^ B2 - Harvest Gold ^ ST - EstateGreen ^ FL - Medium Toreador Red ^ P5 - Aspen Green Metallic ^ UA - Ebony ^ YZ - Oxford White ^ B7 - Zinc Yellow ^ JP - Silver Birch Metallic L2 - True Blue Pearl Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 9113 Paint: Application and ID Paint Code Sticker Location VEHICLE CERTIFICATION LABEL REFERENCE The VC label is located on the left-hand front door or door jamb and is in a similar location on trucks. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 9114 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 9115 Paint: Application and ID DSO Fleet Color Codes Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 9116 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 9117 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Radiator Support > Component Information > Locations Radiator Support: Locations Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Radiator Support > Component Information > Locations > Page 9121 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Application and ID Keyless Entry Module: Application and ID For further information please see Accessories and Optional Equipment, General Module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Application and ID Power Door Lock Control Module: Application and ID For further information please see Accessories and Optional Equipment, General Module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations View 151-16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 9132 Connector View C921 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair Sunroof / Moonroof Motor: Service and Repair REMOVAL 1. Close the roof opening panel. If necessary, refer to Manual Operation. 2. Position the overhead console aside. 3. Remove the roof opening panel motor. 1 Remove the bolts. 2 Remove the roof opening panel motor. Disconnect the electrical connector. NOTE: Make sure that the roof opening panel motor is in the closed position. INSTALLATION 1. Connect the roof opening panel motor electrical connector. 2. With the ignition switch on and the roof opening panel motor still removed, bump the roof opening panel switch one time only towards the close or vent position. 3. Install the roof opening panel motor. 1 Position the roof opening panel motor. 2 Install the roof opening panel bolts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Page 9138 4. Install the overhead console. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams Connector View C912 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 9142 Sunroof / Moonroof Switch: Service and Repair REMOVAL 1. Position the overhead console aside. 2. Remove the roof opening panel control switch. 1 Remove the screws. 2 Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair Sunroof / Moonroof Track: Service and Repair REMOVAL 1. Remove the headliner. 2. Disconnect the roof opening panel motor electrical connector. 3. Remove the roof opening panel frame. 1 Disconnect the four drain hoses. 2 Remove the 18 screws. 3 Remove the roof opening panel frame. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair Sunroof / Moonroof Windguard: Service and Repair REMOVAL 1. Open the roof opening panel to the fully retracted position. 2. Release the two air deflector arms. 3. Remove the air deflector. 1 Detach the two air deflector retainer clips from the U-frame. 2 Remove the air deflector. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Frame: > 05-3-4 > Feb > 05 > Body - Moonroof Squeak or Rattle Noise Sunroof / Moonroof Frame: Customer Interest Body - Moonroof Squeak or Rattle Noise TSB 05-3-4 02/21/05 MOONROOF SQUEAK AND/OR RATTLE NOISE - CORNER INSERT REPAIR FORD: 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2002-2005 Explorer LINCOLN: 2003-2005 Aviator MERCURY: 2002-2005 Mountaineer ISSUE Some 2001-2003 Explorer Sport, 2001-2005 Explorer Sport Trac, 2002-2005 Explorer 4dr/Mountaineer, and 2003-2005 Lincoln Aviator vehicles may exhibit a squeak and/or rattle noise coming from the moonroof area. It is no longer necessary to replace the entire moonroof rail assembly. A new corner insert is now available to correct the condition (Figure 2). ACTION The corner inserts are located in both front corners of the moonroof track and can be accessed by cycling the moonroof glass to the full open position. The original corner insert design had snap tabs that may break off during installation, creating a rattle condition. Replace both of the original inserts and remove any broken tabs left in the track. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Open the moonroof to the full open position. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Frame: > 05-3-4 > Feb > 05 > Body - Moonroof Squeak or Rattle Noise > Page 9157 2. To determine if the corner inserts have broken snap tabs, pull up on the part with a screwdriver and inspect the snap tabs (Figures 1 and 2). 3. Remove both the inserts from the moonroof. Also, examine the track and remove any loose debris (Figure 3). 4. Install a new corner insert on both sides (Figure 4). Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Frame: > 05-3-4 > Feb > 05 > Body - Moonroof Squeak or Rattle Noise > Page 9158 OPERATION DESCRIPTION TIME 050304A 2001-2003 Explorer Sport, 0.3Hr. 2001-2005 Explorer Sport Trac, 2002-2005 Explorer 4dr/Mountaineer, 2003-2005 Lincoln Aviator: Replace Both Of The Moonroof Corner Inserts DEALER CODING CONDITION BASIC PART NO. CODE 78502B36 01 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Frame: > 05-3-4 > Feb > 05 > Body - Moonroof Squeak or Rattle Noise Sunroof / Moonroof Frame: All Technical Service Bulletins Body - Moonroof Squeak or Rattle Noise TSB 05-3-4 02/21/05 MOONROOF SQUEAK AND/OR RATTLE NOISE - CORNER INSERT REPAIR FORD: 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2002-2005 Explorer LINCOLN: 2003-2005 Aviator MERCURY: 2002-2005 Mountaineer ISSUE Some 2001-2003 Explorer Sport, 2001-2005 Explorer Sport Trac, 2002-2005 Explorer 4dr/Mountaineer, and 2003-2005 Lincoln Aviator vehicles may exhibit a squeak and/or rattle noise coming from the moonroof area. It is no longer necessary to replace the entire moonroof rail assembly. A new corner insert is now available to correct the condition (Figure 2). ACTION The corner inserts are located in both front corners of the moonroof track and can be accessed by cycling the moonroof glass to the full open position. The original corner insert design had snap tabs that may break off during installation, creating a rattle condition. Replace both of the original inserts and remove any broken tabs left in the track. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Open the moonroof to the full open position. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Frame: > 05-3-4 > Feb > 05 > Body - Moonroof Squeak or Rattle Noise > Page 9164 2. To determine if the corner inserts have broken snap tabs, pull up on the part with a screwdriver and inspect the snap tabs (Figures 1 and 2). 3. Remove both the inserts from the moonroof. Also, examine the track and remove any loose debris (Figure 3). 4. Install a new corner insert on both sides (Figure 4). Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Frame: > 05-3-4 > Feb > 05 > Body - Moonroof Squeak or Rattle Noise > Page 9165 OPERATION DESCRIPTION TIME 050304A 2001-2003 Explorer Sport, 0.3Hr. 2001-2005 Explorer Sport Trac, 2002-2005 Explorer 4dr/Mountaineer, 2003-2005 Lincoln Aviator: Replace Both Of The Moonroof Corner Inserts DEALER CODING CONDITION BASIC PART NO. CODE 78502B36 01 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Locations View 151-16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Locations > Page 9169 Connector View C921 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams Connector View C357 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams Power Seat Switch: Diagrams Connector View C360 Connector View C369 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service Precautions > Technician Safety Information Power Seat Switch: Technician Safety Information WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTER HANDLING AN AIR BAG MODULE. - NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. - TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). - TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE AND IN THE FRONT SEAT REMOVAL AND INSTALLATION PROCEDURE. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service Precautions > Technician Safety Information > Page 9179 Power Seat Switch: Vehicle Damage Warnings CAUTION: - To prevent damage to the side shield, the clips must be depressed in order to release the side shield from the cushion pan. - Use care when disconnecting the seat cushion side shield from the seat cushion frame so the tabs on the seat cushion side shield are not damaged. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > With Side Air Bags Power Seat Switch: Testing and Inspection With Side Air Bags Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > With Side Air Bags > Page 9182 Seat Adjust Switch, With Side Air Bags Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > With Side Air Bags > Page 9183 Power Seat Switch: Testing and Inspection Without Side Air Bags Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > With Side Air Bags > Page 9184 Seat Adjust Switch, Without Side Air Bags Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch - With Side Air Bag Power Seat Switch: Service and Repair Seat Control Switch - With Side Air Bag Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTER HANDLING AN AIR BAG MODULE. - NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. 1. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Deactivate the supplemental restraint system (SRS). WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. 3. Remove the front seat. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE FRONT SEAT REMOVAL AND INSTALLATION PROCEDURE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch - With Side Air Bag > Page 9187 4. Remove the lumbar support knob. 5. Remove the rear side shield screw. 6. Release the side shield clips. CAUTION: To prevent damage to the side shield, the clips must be depressed in order to release the side shield from the cushion pan. 7. Unhook the side shield from the seat latch. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch - With Side Air Bag > Page 9188 8. Remove the side shield. 1 Disconnect the electrical connector. 2 Remove the side shield. 9. Remove the 6-way power seat switch. 1 Remove the screws. 2 Remove the 6-way power seat switch. INSTALLATION WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES AT THE BEGINNING OF THE REMOVAL PROCEDURE. 1. Install the 6-way power seat switch. 1 Install the 6-way power seat switch. 2 Install the screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch - With Side Air Bag > Page 9189 2. Install the side shield. 1 Install the side shield. 2 Install the electrical connector. 3. Hook the side shield to the seat latch. 4. Install the side shield clips. 5. Install the rear side shield screw. 6. Install the lumbar support knob. 7. Install the front seat. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE FRONT SEAT REMOVAL AND INSTALLATION PROCEDURE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch - With Side Air Bag > Page 9190 8. Reactivate the supplemental restraint system (SRS). WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. 9. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch - With Side Air Bag > Page 9191 Power Seat Switch: Service and Repair Seat Control Switch - Without Side Air Bag REMOVAL 1. Remove the front seat. 2. Remove the lumbar control knob, if equipped. 3. Disconnect the power seat switch electrical connector. 4. Remove the front seat cushion side shield rear screw. 5. Remove the front seat cushion side shield screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch - With Side Air Bag > Page 9192 6. Disconnect the front seat cushion side shield. CAUTION: Use care when disconnecting the seat cushion side shield from the seat cushion frame so the tabs on the seat cushion side shield are not damaged. 7. Remove the front seat cushion side shield. 8. Remove the 6-way power seat switch. - Remove the screws, then remove the 6-way power seat switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Page 9193 Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect Technical Service Bulletin # 03S04S1 Date: 060401 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 9203 Attachment I - Administrative Information OASIS ACTIVATED? Yes. OASIS will be activated for the additional vehicles by April 3, 2006. FSA VIN LIST ACTIVATED? Yes Available through the website by April 5, 2006. Owner names and addresses will be available for the additional vehicles by April 17, 2006. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your new vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the owner a copy of the Customer Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. RELATED DAMAGE Related damage claims are not approved for this program. ADDITIONAL LABOR TIME This repair will require no additional labor time to complete. Claims submitted with "MT" labor will not be accepted for reimbursement. OWNER REFUNDS ^ Ford Motor Company is offering a refund for owner-paid repairs covered by this recall if the repair was performed prior to the date indicated in the Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 9204 reimbursement plan, which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or1 at their option, directly through Ford Motor Company at P.O. Box 6251, Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner-paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Refund claims that include other non-covered repairs, or those judged by Ford to be excessive, will not be accepted for reimbursement. ^ This safety recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 03S04 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refund or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires approval from Special Service Support Center. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Please be aware the BB kit will be utilized on approximately 75% of all repairs while the CA kit will only be used on approximately 25% of the repairs. The DOR/COR for this program is 50309. This number identifies parts ordered for this recall through the Special Service Support Center. RECALL PARTS SUPPORT CENTER The Recall Parts Support Center can be contacted via: ^ Phone Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 9205 ^ E-mail ^ FAX Please be prepared to provide the following information: ^ Dealer Name and P & A code ^ Contact Name ^ Phone number and E-mail address ^ FSA #: 03804 ^ Vehicle Identification Number (if requested) DEALER PRICE For latest prices1 refer to DOES II. PARTS RETENTION AND RETURN Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information OVERVIEW This procedure involves replacement of certain seat recliner assembly attaching hardware on two different style driver seat assemblies. The driver seat will have either a stamped seat back frame or a tubular seat back frame. These seats can be distinguished from one another by slightly lifting the seat back cover and viewing the corner of the seat back frame itself. See Figures 1 and 2. ^ Tubular seatback frames can be identified by a hole in the lower flange where the recliner mechanism attaches to the seatback frame. See Figure 1. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 9206 ^ Stamped seatback frames can be identified by not having the tell-tale hole in the frame that is evident on the tubular seatback frame. See Figure 2. For each type of seat, a different service kit is required. Kits are NOT interchangeable. See Figure 3. ^ Stamped Seatback - The kit consists of: - One (1) UPPER bolt with thread sealer patch (bolt A) - One (1)1-inch spacer (spacer A) ^ Tubular Seatback - The kit consists of: - One (1) UPPER bolt with thread sealer patch (bolt A) - One (1) LOWER bolt without thread sealer patch (bolt B) - One (1) 3/4-inch spacer (spacer B) SERVICE PROCEDURE FOR ALL AFFECTED VEHICLES WARNING: ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIRBAG SUPPLEMENTAL RESTRAINT SYSTEM VEHICLE AND WHEN WORKING NEAR AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF PERSONAL INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. WARNING: TO REDUCE THE RISK OF PERSONAL INJURY, DO NOT USE ANY MEMORY SAVER DEVICES. NOTE: Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 9207 If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner system is being serviced, the supplemental restraint system (SRS) must be depowered. 1. NOTE: Only use the method described to distinguish between driver seatback frame types. Trim and accessories may vary from one seat to another of the same frame configuration. Identify the type of seat back frame by slightly lifting the outside rear corner of the seat back cover and viewing the frame itself. Be sure to procure the proper kit based on the type of seat back frame. 2. NOTE: Go to Step 7 if the vehicle is not equipped with side air bags. Record the preset radio stations. 3. Position the driver seat to its full-forward position. 4. Turn the ignition switch from RUN to OFF. 5. Remove the fuse box cover from the left side of the instrument panel near the driver door hinge area and then remove the applicable airbag fuse. Refer to the following chart to determine which fuse must be removed when working on a vehicle with side air bags. 6. Disconnect the battery negative cable and wait one minute. 7. Position the driver seatback to Its full4orward position. 8. CAUTION: Take care not to damage the seatback trim cover during this step. Unhook the seatback trim cover J-clip. See Figure 4. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 9208 9. Position the driver seatback to a straight-up position. See Figure 5. 10. Carefully pull the outside of the seatback trim cover up to expose the recliner upper bolt. See Figure 6. 11. Remove and discard the upper bolt. 12. Remove and discard the plastic bushing. See Figure 7. 13. CAUTION: Be sure to use the correct spacer for the application. Refer to Figure 3. ^ Spacer A 1-inch on STAMPED seatback frames. ^ Spacer B 3/4-Inch on TUBULAR seatback frames. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 9209 Insert the new spacer from the inboard side of the bolt hole. When Inserted correctly, the spacer should be between the recliner mechanism arm and the seatback frame. See Figure 8. 14. Install the new upper bolt (Bolt A). Tighten the bolt to 45 Nm (33 lb-ft). 15. Carefully install the seatback trim cover over the recliner mechanism arm and into its original position. 16. Position the driver seatback to its full4orward position. 17. Connect the seatback trim cover J-clip. 18. Position the driver seatback to its original position. ^ If the vehicle is equipped with a tubular seatback frame, go to Step 23. ^ If the vehicle is equipped with a stamped seatback frame, continue with the next step. 19. NOTE: If the vehicle is not equipped with side air bags, no further service Is required. Turn the ignition switch from OFF to RUN. 20. Install the airbag fuse and then install the fuse box cover. 21. WARNING: BE SURE THAT NOBODY IS IN THE VEHICLE AND THAT THERE IS NOTHING BLOCKING OR SET IN FRONT OF ANY AIRBAG MODULE WHEN THE BATTERY NEGATIVE CABLE IS CONNECTED. Connect the battery negative cable. 22. Position the driver seat to its original position and program the recorded preset radio stations. THIS COMPLETES SERVICE ON STAMPED SEATBACK FRAMES. FOR TUBULAR SEATBACK FRAMES, PLEASE CONTINUE WITH THE FOLLOWING STEPS. 23. Position the seat cushion side shield aside as follows: ^ Pull off the lumbar support manual adjuster knob, if equipped. ^ Remove two (2) shield attaching screws (three [3] If equipped with power lumbar adjustment). ^ GENTLY unsnap the shield from the seat frame and position the shield out of the way. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 9210 24. Remove and discard the lower bolt from the recliner assembly. See Figure 9. 25. Install the new lower bolt (Bolt B) into the recliner assembly. Tighten the bolt to 45 Nm (33 lb-ft). 26. Install the seat cushion side shield as follows: ^ Align and snap the shield into place. ^ Install the two (2) removed screws. ^ Install the lumbar support adjuster knob. 27. NOTE: If the vehicle is not equipped with side air bags, no further service is required. Turn the ignition switch from OFF to RUN. 28. Install the airbag fuse and then install the fuse box cover. 29. WARNING: BE SURE THAT NOBODY IS IN THE VEHICLE AND THAT THERE IS NOTHING BLOCKING OR SET IN FRONT OF ANY AIRBAG MODULE WHEN THE BATTERY NEGATIVE CABLE IS CONNECTED. Connect the battery negative cable. 30. Position the driver seat to its original position and program the recorded preset radio stations. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 9211 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 9212 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 9213 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect Technical Service Bulletin # 03S04S1 Date: 060401 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 9219 Attachment I - Administrative Information OASIS ACTIVATED? Yes. OASIS will be activated for the additional vehicles by April 3, 2006. FSA VIN LIST ACTIVATED? Yes Available through the website by April 5, 2006. Owner names and addresses will be available for the additional vehicles by April 17, 2006. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your new vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the owner a copy of the Customer Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. RELATED DAMAGE Related damage claims are not approved for this program. ADDITIONAL LABOR TIME This repair will require no additional labor time to complete. Claims submitted with "MT" labor will not be accepted for reimbursement. OWNER REFUNDS ^ Ford Motor Company is offering a refund for owner-paid repairs covered by this recall if the repair was performed prior to the date indicated in the Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 9220 reimbursement plan, which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or1 at their option, directly through Ford Motor Company at P.O. Box 6251, Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner-paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Refund claims that include other non-covered repairs, or those judged by Ford to be excessive, will not be accepted for reimbursement. ^ This safety recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 03S04 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refund or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires approval from Special Service Support Center. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Please be aware the BB kit will be utilized on approximately 75% of all repairs while the CA kit will only be used on approximately 25% of the repairs. The DOR/COR for this program is 50309. This number identifies parts ordered for this recall through the Special Service Support Center. RECALL PARTS SUPPORT CENTER The Recall Parts Support Center can be contacted via: ^ Phone Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 9221 ^ E-mail ^ FAX Please be prepared to provide the following information: ^ Dealer Name and P & A code ^ Contact Name ^ Phone number and E-mail address ^ FSA #: 03804 ^ Vehicle Identification Number (if requested) DEALER PRICE For latest prices1 refer to DOES II. PARTS RETENTION AND RETURN Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information OVERVIEW This procedure involves replacement of certain seat recliner assembly attaching hardware on two different style driver seat assemblies. The driver seat will have either a stamped seat back frame or a tubular seat back frame. These seats can be distinguished from one another by slightly lifting the seat back cover and viewing the corner of the seat back frame itself. See Figures 1 and 2. ^ Tubular seatback frames can be identified by a hole in the lower flange where the recliner mechanism attaches to the seatback frame. See Figure 1. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 9222 ^ Stamped seatback frames can be identified by not having the tell-tale hole in the frame that is evident on the tubular seatback frame. See Figure 2. For each type of seat, a different service kit is required. Kits are NOT interchangeable. See Figure 3. ^ Stamped Seatback - The kit consists of: - One (1) UPPER bolt with thread sealer patch (bolt A) - One (1)1-inch spacer (spacer A) ^ Tubular Seatback - The kit consists of: - One (1) UPPER bolt with thread sealer patch (bolt A) - One (1) LOWER bolt without thread sealer patch (bolt B) - One (1) 3/4-inch spacer (spacer B) SERVICE PROCEDURE FOR ALL AFFECTED VEHICLES WARNING: ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIRBAG SUPPLEMENTAL RESTRAINT SYSTEM VEHICLE AND WHEN WORKING NEAR AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF PERSONAL INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. WARNING: TO REDUCE THE RISK OF PERSONAL INJURY, DO NOT USE ANY MEMORY SAVER DEVICES. NOTE: Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 9223 If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner system is being serviced, the supplemental restraint system (SRS) must be depowered. 1. NOTE: Only use the method described to distinguish between driver seatback frame types. Trim and accessories may vary from one seat to another of the same frame configuration. Identify the type of seat back frame by slightly lifting the outside rear corner of the seat back cover and viewing the frame itself. Be sure to procure the proper kit based on the type of seat back frame. 2. NOTE: Go to Step 7 if the vehicle is not equipped with side air bags. Record the preset radio stations. 3. Position the driver seat to its full-forward position. 4. Turn the ignition switch from RUN to OFF. 5. Remove the fuse box cover from the left side of the instrument panel near the driver door hinge area and then remove the applicable airbag fuse. Refer to the following chart to determine which fuse must be removed when working on a vehicle with side air bags. 6. Disconnect the battery negative cable and wait one minute. 7. Position the driver seatback to Its full4orward position. 8. CAUTION: Take care not to damage the seatback trim cover during this step. Unhook the seatback trim cover J-clip. See Figure 4. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 9224 9. Position the driver seatback to a straight-up position. See Figure 5. 10. Carefully pull the outside of the seatback trim cover up to expose the recliner upper bolt. See Figure 6. 11. Remove and discard the upper bolt. 12. Remove and discard the plastic bushing. See Figure 7. 13. CAUTION: Be sure to use the correct spacer for the application. Refer to Figure 3. ^ Spacer A 1-inch on STAMPED seatback frames. ^ Spacer B 3/4-Inch on TUBULAR seatback frames. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 9225 Insert the new spacer from the inboard side of the bolt hole. When Inserted correctly, the spacer should be between the recliner mechanism arm and the seatback frame. See Figure 8. 14. Install the new upper bolt (Bolt A). Tighten the bolt to 45 Nm (33 lb-ft). 15. Carefully install the seatback trim cover over the recliner mechanism arm and into its original position. 16. Position the driver seatback to its full4orward position. 17. Connect the seatback trim cover J-clip. 18. Position the driver seatback to its original position. ^ If the vehicle is equipped with a tubular seatback frame, go to Step 23. ^ If the vehicle is equipped with a stamped seatback frame, continue with the next step. 19. NOTE: If the vehicle is not equipped with side air bags, no further service Is required. Turn the ignition switch from OFF to RUN. 20. Install the airbag fuse and then install the fuse box cover. 21. WARNING: BE SURE THAT NOBODY IS IN THE VEHICLE AND THAT THERE IS NOTHING BLOCKING OR SET IN FRONT OF ANY AIRBAG MODULE WHEN THE BATTERY NEGATIVE CABLE IS CONNECTED. Connect the battery negative cable. 22. Position the driver seat to its original position and program the recorded preset radio stations. THIS COMPLETES SERVICE ON STAMPED SEATBACK FRAMES. FOR TUBULAR SEATBACK FRAMES, PLEASE CONTINUE WITH THE FOLLOWING STEPS. 23. Position the seat cushion side shield aside as follows: ^ Pull off the lumbar support manual adjuster knob, if equipped. ^ Remove two (2) shield attaching screws (three [3] If equipped with power lumbar adjustment). ^ GENTLY unsnap the shield from the seat frame and position the shield out of the way. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 9226 24. Remove and discard the lower bolt from the recliner assembly. See Figure 9. 25. Install the new lower bolt (Bolt B) into the recliner assembly. Tighten the bolt to 45 Nm (33 lb-ft). 26. Install the seat cushion side shield as follows: ^ Align and snap the shield into place. ^ Install the two (2) removed screws. ^ Install the lumbar support adjuster knob. 27. NOTE: If the vehicle is not equipped with side air bags, no further service is required. Turn the ignition switch from OFF to RUN. 28. Install the airbag fuse and then install the fuse box cover. 29. WARNING: BE SURE THAT NOBODY IS IN THE VEHICLE AND THAT THERE IS NOTHING BLOCKING OR SET IN FRONT OF ANY AIRBAG MODULE WHEN THE BATTERY NEGATIVE CABLE IS CONNECTED. Connect the battery negative cable. 30. Position the driver seat to its original position and program the recorded preset radio stations. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 9227 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 9228 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 9229 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service Precautions > Technician Safety Information Seat Cushion: Technician Safety Information WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTER HANDLING AN AIR BAG MODULE. - NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. - TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). - TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE AND IN THE SEAT REMOVAL AND INSTALLATION PROCEDURE. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service Precautions > Technician Safety Information > Page 9234 Seat Cushion: Vehicle Damage Warnings CAUTION: - Use care when separating the seat cushion trim cover from the hook and loop strip or the hook and loop strip may be torn from the seat cushion foam. - The flex mat J-clips must be installed with the openings facing down or the seat cushion may be damaged. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation Seat Cushion: Service and Repair Removal And Installation Front Seat Cushion Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTER HANDLING AN AIR BAG MODULE. - NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. Seats with side air bags 1. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Deactivate the supplemental restraint system (SRS). WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. All seats 3. Remove the front seat. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE FRONT SEAT REMOVAL AND INSTALLATION PROCEDURE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 9237 4. Remove the seat track. 5. Remove the seat backrest. INSTALLATION WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES AT THE BEGINNING OF THE REMOVAL PROCEDURE. All seats 1. Install the seat backrest. 2. Install the seat track. 3. Install the front seat. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE FRONT SEAT REMOVAL AND INSTALLATION PROCEDURE. Seats with side air bags 4. Reactivate the supplemental restraint system (SRS). WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. 5. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 50/50 Split Bench REMOVAL 1. Fold the rear seat cushion assembly forward. 2. Remove the retaining nut from the end of the link arm and slide the link arm from the stud on the seat cushion frame. 3. Return the seat back assembly to the upright position. 4. Remove the retaining nuts from the front floor attachment. 5. Remove the seat cushion assembly from the vehicle. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 9238 2. Check the active restraint system for correct operation. 60/40 Split Bench REMOVAL 1. Remove the seat. 2. Remove the seat backrest. INSTALLATION 1. To install, reverse the removal procedure. 2. Check the active restraint system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 9239 Seat Cushion: Service and Repair Disassembly and Assembly Manual, With E-Z Entry Special Tool(s) SPECIAL TOOL(S) DISASSEMBLY WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTER HANDLING AN AIR BAG MODULE. - NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. Seats with side air bags 1. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Deactivate the supplemental restraint system (SRS). WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. All seats 3. Remove the seat cushion. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 9240 4. Disconnect the seat cushion trim cover J-clips. 5. Remove the seat cushion trim cover. - Disconnect the seat trim cover from the hook and loop strips. CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip or the hook and loop strip may be torn from the seat cushion foam. 6. Remove the seat cushion. - Disconnect the front and rear J-clips. 7. Remove the flexilator. 1 Remove the flexilator to frame springs. 2 Remove the flexilator. ASSEMBLY Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 9241 WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES AT THE BEGINNING OF THE DISASSEMBLY PROCEDURE. All seats 1. Install the flexilator. 1 Position the flexilator. 2 Install the flexilator to frame springs. 2. Position the seat cushion trim cover on the seat cushion hook and loop strips. 3. Connect the seat cushion trim cover J-clips. 4. Install the seat cushion. Seats with side air bags 5. Reactivate the supplemental restraint system (SRS). WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. 6. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. With Side Air Bag Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 9242 Special Tool(s) SPECIAL TOOL(S) DISASSEMBLY WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTER HANDLING AN AIR BAG MODULE. - NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. 1. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Deactivate the supplemental restraint system (SRS). WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. 3. Remove the seat cushion. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 9243 4. Disconnect the seat cushion trim cover J-clips. 5. Remove the seat cushion frame from the seat cushion foam. 6. Invert the seat cushion trim cover. 7. Remove the swing rods. 1 Remove and discard the hog rings. 2 Remove the swing rods. 8. Remove the seat cushion trim cover. CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip or the hook and loop strip may be torn from the seat cushion foam. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 9244 9. Remove the wire harness from the seat cushion frame. ASSEMBLY WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES AT THE BEGINNING OF THE DISASSEMBLY PROCEDURE. 1. Install the wire harness. 2. Position the seat cushion trim cover. NOTE: When installing a new seat cushion trim cover, it may be necessary to cut a hole for the front seat back pad adjusting cable and the side air bag wiring harness. Use the old seat cushion trim cover as a guide for the location of the hole. 3. Install the seat cushion swing rods. 1 Position the swing rods. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 9245 NOTE: Make sure the ends of the swing rods are positioned beneath the listing wires at the rear of the seat cushion foam. 2 Install the hog rings. 4. Invert the seat cushion trim cover. 5. Connect the seat cushion trim cover J-clips. 6. Install the seat cushion. 7. Reactivate the supplemental restraint system (SRS). WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. 8. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Without Side Air Bag DISASSEMBLY 1. Remove the seat cushion. 2. Disconnect the seat backrest recliner actuator. 1 Remove the screws. 2 Disconnect the seat backrest recliner actuator. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 9246 3. Remove the seat cushion frame from the seat cushion foam. 1 Unhook the seat cushion trim cover J-clips. 2 Remove the seat cushion frame from the seat cushion foam. 4. Invert the seat cushion trim cover. 5. Remove the swing rod to tie-down wire hog rings from the side swing rods (one on each side). 6. Remove and discard the hog rings. 1 Fold back the seat cushion trim cover to expose the hog rings. 2 Remove and discard the hog rings on the front and side trenches. NOTE: The hog rings along the front of the seat are shown, the hog rings along either side are similar. 7. Remove the swing rods. 8. Remove the power seat wiring harness. 1 Disconnect the pin-type retainers. 2 Remove the power seat wiring harness. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 9247 9. Remove the flexilator. 1 Remove the flexilator springs. 2 Remove the flexilator. 10. Remove the seat backrest recliner roll pins and remove the seat backrest recliners. 11. Disconnect the seat backrest recliners from the seat backrest recliner actuator. 1 Disconnect the seat backrest recliner actuator cable housings from the seat backrest recliners. 2 Unhook the seat backrest recliner actuator cables from the seat backrest recliners. ASSEMBLY 1. Connect the seat backrest recliners to the seat backrest recliner actuator. 1 Hook the seat backrest recliner actuator cables to the seat backrest recliners. 2 Connect the seat backrest recliner actuator cable housings to the seat backrest recliners. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 9248 2. Install the seat backrest recliner roll pins. 3. Install the flexilator. 1 Position the flexilator. 2 Install the flexilator springs. 4. Install the power seat wiring harness. 1 Position the power seat wiring harness. 2 Install the pin-type retainers. 5. Install the front swing rod. 6. Install the swing rods. NOTE: Make sure the swing rods are seated under the boarder wire in the foam near the back of the seat cushion. 7. Install the hog rings. 1 Fold back the seat cushion trim cover to the hog ring installation position. 2 Hog ring the center of the front swing rod to the tie-down rod in the seat cushion. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 9249 3 Hog ring the front swing rod to tie-down wire outboard sides. NOTE: The hog rings along the front of the seat are shown; the hog rings along either side are similar. 8. Hog ring the side swing rods (one on each side) to the tie-down wire. 9. Invert the seat cushion trim cover. 10. Set the hook and loop fasteners. 11. Install the seat cushion foam to the seat cushion frame. 12. Install the seat cushion frame. 1 Position the seat cushion frame. 2 Hook the seat cushion trim cover J-clips. 13. Connect the seat backrest recliner actuator. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 9250 1 Connect the seat backrest recliner actuator. 2 Install the screws. Tighten until the screws are fully seated. 14. Install the seat cushion. 40 Percent Portion of 60/40 Split Bench DISASSEMBLY 1. Remove the rear seat. 2. Remove the rear seat legs. 1 Remove the pivot bolts. 2 Remove the rear seat legs. 3. Unhook the seat cushion trim cover J-clips. 4. Remove the seat cushion trim cover. - Separate the seat cushion trim cover from the hook and loop strip. CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip or the hook and loop strip may be torn from the seat cushion foam. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 9251 5. Remove the seat cushion flex mat. 1 Unhook the rear flex mat J-clip. 2 Unhook the front flex mat J-clip. 3 Remove the seat cushion flex mat. NOTE: Use the brackets on the seat cushion frame to obtain the necessary leverage to unhook the rear flex mat J-clip. ASSEMBLY 1. Install the seat cushion flex mat. 1 Position the seat cushion flex mat. 2 Hook the front flex mat J-clip. 3 Hook the rear flex mat J-clip. CAUTION: The flex mat J-clips must be installed with the openings facing down or the seat cushion may be damaged. NOTE: Use the brackets on the seat cushion frame to obtain the necessary leverage to hook the rear flex mat J-clip. 2. Position the seat cushion trim cover on the seat cushion hook and loop strips. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 9252 3. Hook the seat cushion trim cover J-clips. 4. Install the rear seat riser pivot bolts. 1 Position the rear seat legs. 2 Install the rear seat riser pivot bolts. 5. Install the rear seat. 50/50 Split Bench DISASSEMBLY 1. Remove the rear seat cushion. 2. Remove the pivot legs. 1 Remove the bolts. 2 Remove the pivot legs. 3. Remove the seat cushion trim cover. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 9253 - Disconnect the pin-type retainers. 4. Remove the seat cushion foam from the seat cushion frame. ASSEMBLY 1. To assemble, reverse the disassembly procedure. 60 Percent Portion of 60/40 Split Bench DISASSEMBLY 1. Remove the rear seat backrest. 2. Remove the seat cushion legs. 1 Remove the pivot bolts. 2 Remove the seat cushion legs. 3. Remove the seat cushion frame from the seat cushion foam. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 9254 1 Unhook the seat cushion trim cover J-clips. 2 Remove the seat cushion frame from the seat cushion foam. 4. Invert the seat cushion trim cover. 5. Remove the seat cushion trim cover. - Separate the seat cushion trim cover from the hook and loop strip. CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip or the hook and loop strip may be torn from the seat cushion foam. 6. Remove the seat cushion flex mats. 1 Unhook the rear flex mat J-clips. 2 Unhook the front flex mat J-clips. 3 Remove the seat cushion flex mats. NOTE: Use the brackets on the seat cushion frame to obtain the necessary leverage to unhook the rear flex mat J-clip. ASSEMBLY 1. Install the seat cushion flex mats. 1 Position the seat cushion flex mats. 2 Hook the front flex mat J-clips. 3 Hook the rear flex mat J-clips. CAUTION: The flex mat J-clips must be installed with the openings facing down or the seat cushion foam may be damaged. NOTE: Use the brackets on the seat cushion frame to obtain the necessary leverage to hook the rear flex mat clip. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 9255 2. Position the seat cushion trim cover on the seat cushion hook and loop strips. 3. Install the seat cushion frame into the seat cushion foam. 1 Position the seat cushion frame. 2 Hook the seat cushion trim cover J-clips. 4. Install the seat cushion legs. 1 Position the seat cushion legs. 2 Install the rear seat riser pivot bolts. 5. Install the rear seat backrest. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service Precautions Seat Track: Service Precautions WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTER HANDLING AN AIR BAG MODULE. - NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. - TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). - TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. - TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE FRONT SEAT REMOVAL AND INSTALLATION PROCEDURE. - TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES AT THE BEGINNING OF THE REMOVAL PROCEDURE. - TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Front Manual Seat Track: Service and Repair Seat Track - Front Manual Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTER HANDLING AN AIR BAG MODULE. - NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. Seats with side air bags 1. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Deactivate the supplemental restraint system (SRS). WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. All seats 3. Remove the front seat. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Front Manual > Page 9261 WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE FRONT SEAT REMOVAL AND INSTALLATION PROCEDURE. 4. Remove the safety belt buckle support. 1 Remove the nut. 2 Remove the bolt. 3 Remove the safety belt buckle support. Seats with E-Z entry 5. Unfasten the seat backrest spring clip. All seats 6. Remove the seat track to seat cushion front bolts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Front Manual > Page 9262 7. Remove the front seat track. 1 Remove the seat track to seat cushion rear bolts. 2 Remove the front seat track. INSTALLATION WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES AT THE BEGINNING OF THE REMOVAL PROCEDURE. All seats 1. Install the front seat track front bolts. 1 Position the front seat track. 2 Install the inboard bolt. 3 Install the outboard bolt. 2. Install the front seat track rear bolts. 1 Install the inboard bolt. 2 Install the outboard bolt. Seats with E-Z entry Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Front Manual > Page 9263 3. Fasten the seat backrest spring clips. All seats 4. Install the safety belt buckle support onto the slide bar. 1 Position the safety belt buckle support onto the slide bar. 2 Using the special tool, install the safety belt buckle support bolt. 3 Remove the safety belt buckle support from the vise. 5. Install the safety belt buckle slide bar onto the seat. 1 Position the safety belt buckle slide bar to the seat. 2 Install the nut and bolt. 6. Install the front seat. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE FRONT SEAT REMOVAL AND INSTALLATION PROCEDURE. Seats with side air bags 7. Reactivate the supplemental restraint system (SRS). WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. 8. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Front Manual > Page 9264 Seat Track: Service and Repair Seat Track - Front Power Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTER HANDLING AN AIR BAG MODULE. - NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. Seats with side air bags 1. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Deactivate the supplemental restraint system (SRS). WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. All seats 3. Remove the front seat. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Front Manual > Page 9265 WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE FRONT SEAT REMOVAL AND INSTALLATION PROCEDURE. 4. Remove the safety belt buckle support. 1 Remove the nut. 2 Remove the bolt. 3 Remove the safety belt buckle support. 5. Disconnect the seat track wiring harness electrical connector. 6. Remove the seat track. 1 Remove the bolts. 2 Remove the seat track. INSTALLATION WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES AT THE BEGINNING OF THE REMOVAL PROCEDURE. All seats Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Front Manual > Page 9266 1. Install the seat track. NOTE: When installing the power seat track, start at the corner with the round hole and work around the seat base in a horseshoe pattern. 2. Connect the seat track wiring harness electrical connectors. 3. Install the safety belt buckle support onto the slide bar. 1 Position the safety belt buckle support onto the slide bar. 2 Using the special tool, install the safety belt buckle support bolt. 3 Remove the safety belt buckle support from the vise. 4. Install the safety belt buckle slide bar onto the seat. 1 Position the safety belt buckle slide bar to the seat. 2 Install the nut and bolt. 5. Install the front seat. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track - Front Manual > Page 9267 INSTRUCTIONS IN THE FRONT SEAT REMOVAL AND INSTALLATION PROCEDURE. Seats with side air bags 6. Reactivate the supplemental restraint system (SRS). WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. 7. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Page 9268 Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Driver Side Connector View C505 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Driver Side > Page 9274 Connector View C605 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Driver Side Power Door Lock Switch: Testing and Inspection Driver Side Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Driver Side > Page 9277 Door Lock Switch, Driver Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Driver Side > Page 9278 Power Door Lock Switch: Testing and Inspection Passenger Side Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Driver Side > Page 9279 Door Lock Switch, Passenger Side Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams Connector View C527 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Page 9283 Power Mirror Switch: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Page 9284 Exterior Rear View Mirror Switch Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Page 9285 Exterior Rear View Mirror Switch Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams Power Seat Switch: Diagrams Connector View C360 Connector View C369 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service Precautions > Technician Safety Information Power Seat Switch: Technician Safety Information WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTER HANDLING AN AIR BAG MODULE. - NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. - TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). - TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE AND IN THE FRONT SEAT REMOVAL AND INSTALLATION PROCEDURE. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service Precautions > Technician Safety Information > Page 9291 Power Seat Switch: Vehicle Damage Warnings CAUTION: - To prevent damage to the side shield, the clips must be depressed in order to release the side shield from the cushion pan. - Use care when disconnecting the seat cushion side shield from the seat cushion frame so the tabs on the seat cushion side shield are not damaged. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > With Side Air Bags Power Seat Switch: Testing and Inspection With Side Air Bags Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > With Side Air Bags > Page 9294 Seat Adjust Switch, With Side Air Bags Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > With Side Air Bags > Page 9295 Power Seat Switch: Testing and Inspection Without Side Air Bags Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > With Side Air Bags > Page 9296 Seat Adjust Switch, Without Side Air Bags Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch - With Side Air Bag Power Seat Switch: Service and Repair Seat Control Switch - With Side Air Bag Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTER HANDLING AN AIR BAG MODULE. - NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. 1. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Deactivate the supplemental restraint system (SRS). WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. 3. Remove the front seat. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE FRONT SEAT REMOVAL AND INSTALLATION PROCEDURE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch - With Side Air Bag > Page 9299 4. Remove the lumbar support knob. 5. Remove the rear side shield screw. 6. Release the side shield clips. CAUTION: To prevent damage to the side shield, the clips must be depressed in order to release the side shield from the cushion pan. 7. Unhook the side shield from the seat latch. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch - With Side Air Bag > Page 9300 8. Remove the side shield. 1 Disconnect the electrical connector. 2 Remove the side shield. 9. Remove the 6-way power seat switch. 1 Remove the screws. 2 Remove the 6-way power seat switch. INSTALLATION WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES AT THE BEGINNING OF THE REMOVAL PROCEDURE. 1. Install the 6-way power seat switch. 1 Install the 6-way power seat switch. 2 Install the screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch - With Side Air Bag > Page 9301 2. Install the side shield. 1 Install the side shield. 2 Install the electrical connector. 3. Hook the side shield to the seat latch. 4. Install the side shield clips. 5. Install the rear side shield screw. 6. Install the lumbar support knob. 7. Install the front seat. WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE FRONT SEAT REMOVAL AND INSTALLATION PROCEDURE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch - With Side Air Bag > Page 9302 8. Reactivate the supplemental restraint system (SRS). WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, NOTES, AND INSTRUCTIONS IN THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION/REACTIVATION PROCEDURE. 9. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch - With Side Air Bag > Page 9303 Power Seat Switch: Service and Repair Seat Control Switch - Without Side Air Bag REMOVAL 1. Remove the front seat. 2. Remove the lumbar control knob, if equipped. 3. Disconnect the power seat switch electrical connector. 4. Remove the front seat cushion side shield rear screw. 5. Remove the front seat cushion side shield screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch - With Side Air Bag > Page 9304 6. Disconnect the front seat cushion side shield. CAUTION: Use care when disconnecting the seat cushion side shield from the seat cushion frame so the tabs on the seat cushion side shield are not damaged. 7. Remove the front seat cushion side shield. 8. Remove the 6-way power seat switch. - Remove the screws, then remove the 6-way power seat switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Page 9305 Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams Connector View C456 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams > Page 9309 Power Trunk / Liftgate Lock Switch: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams > Page 9310 Liftgate Door Lock Switch Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams Connector View C912 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 9314 Sunroof / Moonroof Switch: Service and Repair REMOVAL 1. Position the overhead console aside. 2. Remove the roof opening panel control switch. 1 Remove the screws. 2 Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Description and Operation Sound Proofing / Insulation: Description and Operation INSULATION Insulation is installed: - under the hood. - above and below the instrument panel. - at the A-pillar lower trim panel. - over the front and rear tunnel. - over the front and rear floor pans. - inside the B-pillar. - inside the C-pillar. - inside the D-pillar (Explorer Sport). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Hinge > Component Information > Technical Service Bulletins > Customer Interest for Tailgate Hinge: > 02-3-5 > Feb > 02 > Tailgate - Squeaking/Binding Condition Tailgate Hinge: Customer Interest Tailgate - Squeaking/Binding Condition Article No. 02-3-5 02/18/02 ^ BODY - "SQUEAK" OR BIND FROM TAILGATE ^ NOISE - "SQUEAK" OR BIND FROM TAILGATE FORD: 1997-1998 F SUPER DUTY 1997-2002 F-150, RANGER 1999-2002 SUPER DUTY F SERIES 2001-2002 EXPLORER SPORT TRAC ISSUE Some vehicles may exhibit a "Squeak" or Bind condition of the Tailgate. This may be caused by the grease on the tailgate hinges that may wash out prematurely causing a squeak or binding condition. ACTION Verify condition. Apply Silicone grease to correct the condition. Refer the the following Service Procedure for details. SERVICE PROCEDURE 1. Remove tail gate from the vehicle. 2. Remove plastic inserts from tail gate hinge cups. 3. Clean inside of hinge cups. 4. Apply grease (use only XG-3), to all inside surfaces of right and left side hinge cups and right and left side body side pins (Figure 1) and re-install plastic inserts into tail gate. 5. Reinstall the tail gate Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Hinge > Component Information > Technical Service Bulletins > Customer Interest for Tailgate Hinge: > 02-3-5 > Feb > 02 > Tailgate - Squeaking/Binding Condition > Page 9327 Parts Block OTHER APPLICABLE ARTICLES: NONE OPERATION DESCRIPTION TIME 020305A Apply Grease As 0.3 Hr. Instructed In Service Procedure DEALER CODING CONDITION BASIC PART NO. CODE 99430B22 41 OASIS CODES: 111000,112600, 702000, 702200 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Hinge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Hinge: > 02-3-5 > Feb > 02 > Tailgate - Squeaking/Binding Condition Tailgate Hinge: All Technical Service Bulletins Tailgate - Squeaking/Binding Condition Article No. 02-3-5 02/18/02 ^ BODY - "SQUEAK" OR BIND FROM TAILGATE ^ NOISE - "SQUEAK" OR BIND FROM TAILGATE FORD: 1997-1998 F SUPER DUTY 1997-2002 F-150, RANGER 1999-2002 SUPER DUTY F SERIES 2001-2002 EXPLORER SPORT TRAC ISSUE Some vehicles may exhibit a "Squeak" or Bind condition of the Tailgate. This may be caused by the grease on the tailgate hinges that may wash out prematurely causing a squeak or binding condition. ACTION Verify condition. Apply Silicone grease to correct the condition. Refer the the following Service Procedure for details. SERVICE PROCEDURE 1. Remove tail gate from the vehicle. 2. Remove plastic inserts from tail gate hinge cups. 3. Clean inside of hinge cups. 4. Apply grease (use only XG-3), to all inside surfaces of right and left side hinge cups and right and left side body side pins (Figure 1) and re-install plastic inserts into tail gate. 5. Reinstall the tail gate Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Hinge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Hinge: > 02-3-5 > Feb > 02 > Tailgate - Squeaking/Binding Condition > Page 9333 Parts Block OTHER APPLICABLE ARTICLES: NONE OPERATION DESCRIPTION TIME 020305A Apply Grease As 0.3 Hr. Instructed In Service Procedure DEALER CODING CONDITION BASIC PART NO. CODE 99430B22 41 OASIS CODES: 111000,112600, 702000, 702200 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair > Tailgate Latch Tailgate Latch: Service and Repair Tailgate Latch REMOVAL 1. Remove the tailgate trim panel. 1 Remove the screws. 2 Remove the pin-type retainers. 2. Remove the tailgate latch bolts. 3. Remove the tailgate latch actuating rod guide. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair > Tailgate Latch > Page 9338 4. Remove the tailgate latch. 1 Release the actuating rod. 2 Remove the tailgate latch. INSTALLATION 1. To install, reverse the removal procedure. - If necessary, use Multi-Purpose Grease Spray F5AZ-19G209-AA or equivalent meeting Ford specification ESR-M1C159-A to lubricate the latches. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair > Tailgate Latch > Page 9339 Tailgate Latch: Service and Repair Tailgate Latch Remote Control REMOVAL 1. Remove the tailgate trim panel. 1 Remove the screws. 2 Remove the pin-type retainers. 2. Release the tailgate latch actuating rods from the remote control. NOTE: Make sure the liftgate latch release rod is not preloading the latch. It should be clipped in a relaxed state with no slack. 3. Remove the tailgate latch remote control nuts. 4. Remove the tailgate latch remote control. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair > Tailgate Latch > Page 9340 INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Service and Repair Tailgate Lock Cylinder: Service and Repair REMOVAL 1. Remove the tailgate release handle. 2. Remove the clip and the lock cylinder. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service and Repair Tailgate Release Handle: Service and Repair REMOVAL 1. Remove the tailgate trim panel. 1 Remove the screws. 2 Remove the pin-type retainers. 2. Disconnect the tailgate latch actuating rods from the remote control. 1 Open the clips. 2 Disconnect the tailgate latch actuating rods. 3. Remove the tailgate latch remote control nuts. 4. Remove the tailgate latch release handle. - Transfer parts as necessary. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service and Repair > Page 9347 INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Cover > Component Information > Service and Repair > Tonneau Cover Lock Cylinder Truck Bed Cover: Service and Repair Tonneau Cover Lock Cylinder REMOVAL 1. Remove the tonneau cover release cable. 2. Remove the tonneau cover lock cylinder. 1 Remove the retaining clip. 2 Remove the lock cylinder. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Cover > Component Information > Service and Repair > Tonneau Cover Lock Cylinder > Page 9353 Truck Bed Cover: Service and Repair Tonneau Cover Latch Release Cable REMOVAL NOTE: Front tonneau cover latch release cable shown, rear tonneau cover latch release cable similar. 1. Remove the four bolts (two each side) and position the LH and RH tonneau cover latches aside. NOTE: Mark location of bolts to latch bracket. 2. Disconnect the tonneau cover cables from the LH and RH latches. 1 Disconnect the cable conduit. 2 Remove the cable end from the lever arm. NOTE: Tonneau cover release cables are not reuseable. Discard cables once removed. 3. Disconnect the lock actuator housing from the lock cylinder and remove the tonneau cover latch release cable. - Twist and pull upward. INSTALLATION Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Cover > Component Information > Service and Repair > Tonneau Cover Lock Cylinder > Page 9354 1. Route the new tonneau cover latch release cable through the tonneau cover. 2. Install the lock actuator housing. - Twist and push downward. The lock actuator housing will snap into place. NOTE: Install the lock actuator housing into place with the molded line facing outward. 3. Connect the tonneau cover latch release cables to the LH and RH latches. 1 Insert the cable end through the lever arm. 2 Snap the cable conduit into the opening. 4. Position the tonneau cover latches and Install the four bolts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair COWL PANEL GRILLE Removal and Installation 1. Disconnect the driver side windshield washer hose from inside the engine compartment. 2. Remove the windshield wiper pivot arms. 1. Slide the clip so the windshield wiper pivot arm will clear the windshield wiper pivot shaft. 2. Pull the windshield wiper pivot arm from the windshield wiper pivot shaft. 3. Remove the cowl grille screw. 4. Remove the driver side cowl grille. - Pull up on the cowl grille to disengage the clips. 5. Remove the passenger side cowl grille. - Pull up on the cowl grille to disengage the clips and disconnect the washer hose. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9369 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9370 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9371 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9372 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9373 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9374 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9375 Attachment III - Technical Information Table of Contents Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9376 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9377 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9378 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9379 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9380 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9381 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9382 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9383 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9384 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9385 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9386 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9387 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9388 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9389 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9390 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9391 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9392 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9393 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9394 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): Recalls Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 9399 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9405 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9406 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9407 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9408 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9409 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9410 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9411 Attachment III - Technical Information Table of Contents Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9412 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9413 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9414 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9415 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9416 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9417 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9418 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9419 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9420 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9421 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9422 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9423 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9424 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9425 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9426 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9427 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9428 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9429 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9430 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): All Technical Service Bulletins Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 9435 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Deactivator Switch Connector View C1025 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Deactivator Switch > Page 9438 Connector View C278 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Technician Safety Information Brake Switch (Cruise Control): Technician Safety Information WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Technician Safety Information > Page 9441 Brake Switch (Cruise Control): Vehicle Damage Warnings CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Page 9442 Brake Switch (Cruise Control): Description and Operation Brake Pressure Applied Brake Deactivator Switch The Brake Pressure Applied (BPA) switch also sometimes called the brake deactivator switch for vehicle speed control deactivation. Is a normally closed switch, witch supplies battery positive voltage (B+) to the PCM when the brake pedal is NOT applied. When the brake pedal is depressed, the normally closed switch will open and power is removed from the PCM. On some applications the normally closed BPA switch along with the normally open brake pedal position (BPP) switch are used for a brake rationality test within the PCM. The PCM misfire monitor profile learn function can be disable if a brake switch failure occurs. If one or both brake pedal inputs to the PCM did not change states when they were expected to a diagnostic trouble code P1572 can be set by the PCM strategy. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Page 9443 Brake Switch (Cruise Control): Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the speed control deactivator switch electrical connector. 3. Remove the speed control deactivator switch. WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. INSTALLATION 1. To install, reverse the removal procedure. ^ Bleed the brake system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Diagrams Connector View C257 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Diagrams Connector View C122 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Diagrams > Page 9450 Cruise Control Servo: Service and Repair REMOVAL 1. Disconnect the electrical connector. 2. Depress the locking tab and rotate the speed control cable cap to remove. 3. Disconnect the speed control cable from the speed control servo pulley. 1 Gently push the retaining spring. 2 Disconnect the speed control cable slug. 4. Remove the bolt and the speed control servo and bracket. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Diagrams > Page 9451 5. Remove the bolts and separate the bracket from the speed control servo. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Make sure the rubber seal is fully seated onto the speed control cable cap. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Adjustments Cruise Control Servo Cable: Adjustments 1. Remove the speed control actuator cable clip. 2. Adjust the speed control actuator cable. 1 Hold the throttle body cam is in the closed position. 2 Pull on the speed control actuator cable housing to remove any slack. 3 Back off the speed control actuator cable one notch and install the clip. NOTE: ^ The speed control actuator cable must not be pulled tight for correct operation. ^ The throttle body cam will automatically spring set to the closed position. The throttle body cam must be in the closed position. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Adjustments > Page 9455 Cruise Control Servo Cable: Service and Repair REMOVAL Early production vehicles 1. Remove the accelerator cable snow shield. 1 Detach the cable. 2 Remove the bolts. 3 Remove the accelerator cable snow shield. 2. Separate the speed control cable from the intake manifold. 1 Remove the bolt. 2 Disconnect the cable from the throttle linkage. Late production vehicles 3. Remove the bolts and the accelerator cable snow shield. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Adjustments > Page 9456 4. Separate the speed control cable from the intake manifold. 1 Disconnect the cable from the throttle linkage. 2 Depress the locking tabs and separate the speed control cable from the intake manifold. All vehicles 5. Depress the locking tab and rotate the speed control cable cap to remove. 6. Disconnect the speed control cable from the speed control servo pulley and remove the speed control cable. 1 Gently push the retaining spring. 2 Disconnect the speed control cable slug from the speed control servo pulley. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Adjustments > Page 9457 ^ On early production vehicles, adjust the speed control cable. NOTE: Make sure the rubber seal is fully seated onto the speed control cable cap Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair Cruise Control Switch: Service and Repair REMOVAL 1. Remove the steering wheel. 2. Remove the screws and the steering wheel rear cover. 3. Remove the ribbon harness from the clips. 4. Disconnect the horn contact electrical connectors. 5. Remove the screws and the right side horn contact. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Page 9461 6. Remove the screws and the speed control switch assembly. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9471 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9472 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9473 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9474 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9475 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9476 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9477 Attachment III - Technical Information Table of Contents Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9478 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9479 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9480 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9481 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9482 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9483 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9484 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9485 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9486 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9487 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9488 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9489 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9490 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9491 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9492 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9493 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9494 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9495 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9496 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): Recalls Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 9501 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9507 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9508 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9509 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9510 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9511 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9512 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9513 Attachment III - Technical Information Table of Contents Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9514 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9515 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9516 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9517 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9518 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9519 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9520 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9521 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9522 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9523 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9524 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9525 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9526 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9527 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9528 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9529 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9530 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9531 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9532 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): All Technical Service Bulletins Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 9537 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Deactivator Switch Connector View C1025 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Deactivator Switch > Page 9540 Connector View C278 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Technician Safety Information Brake Switch (Cruise Control): Technician Safety Information WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Technician Safety Information > Page 9543 Brake Switch (Cruise Control): Vehicle Damage Warnings CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Page 9544 Brake Switch (Cruise Control): Description and Operation Brake Pressure Applied Brake Deactivator Switch The Brake Pressure Applied (BPA) switch also sometimes called the brake deactivator switch for vehicle speed control deactivation. Is a normally closed switch, witch supplies battery positive voltage (B+) to the PCM when the brake pedal is NOT applied. When the brake pedal is depressed, the normally closed switch will open and power is removed from the PCM. On some applications the normally closed BPA switch along with the normally open brake pedal position (BPP) switch are used for a brake rationality test within the PCM. The PCM misfire monitor profile learn function can be disable if a brake switch failure occurs. If one or both brake pedal inputs to the PCM did not change states when they were expected to a diagnostic trouble code P1572 can be set by the PCM strategy. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Page 9545 Brake Switch (Cruise Control): Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the speed control deactivator switch electrical connector. 3. Remove the speed control deactivator switch. WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. INSTALLATION 1. To install, reverse the removal procedure. ^ Bleed the brake system. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Diagrams Connector View C257 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair Cruise Control Switch: Service and Repair REMOVAL 1. Remove the steering wheel. 2. Remove the screws and the steering wheel rear cover. 3. Remove the ribbon harness from the clips. 4. Disconnect the horn contact electrical connectors. 5. Remove the screws and the right side horn contact. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Page 9552 6. Remove the screws and the speed control switch assembly. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > Customer Interest for Audible Warning Device: > 01-21-13 > Oct > 01 > Ignition Switch - High Turning Effort/MIL ON/DTC's Set Audible Warning Device: Customer Interest Ignition Switch - High Turning Effort/MIL ON/DTC's Set Article No. 01-21-13 10/29/01 ^ DRIVEABILITY - DIAGNOSTIC TROUBLE CODES (DTC) P0500, P1502 AND/OR U1039 CONTINENTAL MODELS ONLY - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN TURNING IGNITION SWITCH ^ ELECTRICAL - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN TURNING IGNITION SWITCH FORD: 1998-2002 CROWN VICTORIA, MUSTANG, TAURUS 1998-1999 F-250 LD 1998-2001 EXPLORER 1998-2002 E SERIES, EXPEDITION, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT 2001-2002 EXPLORER SPORT TRAC LINCOLN: 1998-2002 CONTINENTAL, TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 1998-2002 GRAND MARQUIS, SABLE 1998-2001 MOUNTAINEER ISSUE Some ignition switch lock cylinder assemblies may exhibit the following highly intermittent conditions: ^ Roughness and/or excessive effort in turning the key from RUN to START position. ^ Key does not fully return from START to RUN after starting vehicle. This may result in intermittent accessory function. ^ Continental ONLY - A malfunction indicator lamp may illuminate with diagnostic trouble codes P0500, P1502 and UlO3g stored in the Powertrain Control Modules (PCM) memory. This may be caused by a Key-In-Ignition warning chime switch. ACTION Replace the KEY-IN-IGNITION WARNING CHIME SWITCH located on the ignition switch lock cylinder with revised pant XL2Z-11A127-AB. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Disconnect the battery ground cable and wait at least one minute. 2. Insent the ignition key and turn it to the RUN position. 3. Insert a punch into the access hole (located in the lower steering column shroud, below the lock cylinder) and press the release button while pulling out the ignition switch lock cylinder. NOTE SOME VEHICLES DO NOT HAVE AN ACCESS HOLE AND REQUIRE LOWER SHROUD REMOVAL. REFER TO THE APPROPRIATE MODEL WORKSHOP MANUAL, IGNITION SWITCH LOCK CYLINDER REMOVAL AND INSTALLATION SECTION 211 IF ADDITIONAL DETAIL IS REQUIRED. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > Customer Interest for Audible Warning Device: > 01-21-13 > Oct > 01 > Ignition Switch - High Turning Effort/MIL ON/DTC's Set > Page 9562 4. Remove the Plastic Key chime warning switch by prying upward on the plastic retainer, while sliding the switch away from the key insertion end (Figure 1). Refer to the appropriate model Workshop Manual, Key-in-ignition warning switch removal and installation section located in Section 413 if additional detail is required. 5. Install a new Key-In-Ignition warning chime switch XL2Z-11A127-AB and reinstall lock cylinder. 6. Verify proper function of the Ignition Switch Lock Cylinder and Key-In-Ignition warning chime switch. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 012113A Replace The 0.3 Hr. Key-In-Ignition Warning Chime Switch DEALER CODING CONDITION BASIC PART NO. CODE 11A127 42 OASIS CODES: 102000, 112000, 202000, 203000, 204000, 204200, 205000, 206000, 207000, 208000, 208999, 301000, 302000, 497000, 504000, 601300, 603300, 698298 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Audible Warning Device: > 01-21-13 > Oct > 01 > Ignition Switch - High Turning Effort/MIL ON/DTC's Set Audible Warning Device: All Technical Service Bulletins Ignition Switch - High Turning Effort/MIL ON/DTC's Set Article No. 01-21-13 10/29/01 ^ DRIVEABILITY - DIAGNOSTIC TROUBLE CODES (DTC) P0500, P1502 AND/OR U1039 CONTINENTAL MODELS ONLY - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN TURNING IGNITION SWITCH ^ ELECTRICAL - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN TURNING IGNITION SWITCH FORD: 1998-2002 CROWN VICTORIA, MUSTANG, TAURUS 1998-1999 F-250 LD 1998-2001 EXPLORER 1998-2002 E SERIES, EXPEDITION, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT 2001-2002 EXPLORER SPORT TRAC LINCOLN: 1998-2002 CONTINENTAL, TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 1998-2002 GRAND MARQUIS, SABLE 1998-2001 MOUNTAINEER ISSUE Some ignition switch lock cylinder assemblies may exhibit the following highly intermittent conditions: ^ Roughness and/or excessive effort in turning the key from RUN to START position. ^ Key does not fully return from START to RUN after starting vehicle. This may result in intermittent accessory function. ^ Continental ONLY - A malfunction indicator lamp may illuminate with diagnostic trouble codes P0500, P1502 and UlO3g stored in the Powertrain Control Modules (PCM) memory. This may be caused by a Key-In-Ignition warning chime switch. ACTION Replace the KEY-IN-IGNITION WARNING CHIME SWITCH located on the ignition switch lock cylinder with revised pant XL2Z-11A127-AB. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Disconnect the battery ground cable and wait at least one minute. 2. Insent the ignition key and turn it to the RUN position. 3. Insert a punch into the access hole (located in the lower steering column shroud, below the lock cylinder) and press the release button while pulling out the ignition switch lock cylinder. NOTE SOME VEHICLES DO NOT HAVE AN ACCESS HOLE AND REQUIRE LOWER SHROUD REMOVAL. REFER TO THE APPROPRIATE MODEL WORKSHOP MANUAL, IGNITION SWITCH LOCK CYLINDER REMOVAL AND INSTALLATION SECTION 211 IF ADDITIONAL DETAIL IS REQUIRED. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Audible Warning Device: > 01-21-13 > Oct > 01 > Ignition Switch - High Turning Effort/MIL ON/DTC's Set > Page 9568 4. Remove the Plastic Key chime warning switch by prying upward on the plastic retainer, while sliding the switch away from the key insertion end (Figure 1). Refer to the appropriate model Workshop Manual, Key-in-ignition warning switch removal and installation section located in Section 413 if additional detail is required. 5. Install a new Key-In-Ignition warning chime switch XL2Z-11A127-AB and reinstall lock cylinder. 6. Verify proper function of the Ignition Switch Lock Cylinder and Key-In-Ignition warning chime switch. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 012113A Replace The 0.3 Hr. Key-In-Ignition Warning Chime Switch DEALER CODING CONDITION BASIC PART NO. CODE 11A127 42 OASIS CODES: 102000, 112000, 202000, 203000, 204000, 204200, 205000, 206000, 207000, 208000, 208999, 301000, 302000, 497000, 504000, 601300, 603300, 698298 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > Page 9569 Audible Warning Device: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Application and ID Audible Warning Device Control Module: Application and ID For further information please see Accessories and Optional Equipment, General Module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. NOTE: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9577 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number or the component name in one of the the A-Z Component Lists, the Component Location description for that component can easily be found. See: Locations/Component Locations/A-Z Component List Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9578 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9579 the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9580 that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9581 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9582 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9583 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9584 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9585 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9586 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9587 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9588 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9589 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9590 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9591 Systems Overview Wire Color Code Identification Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9592 OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9593 Cigarette Lighter: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9594 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9595 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9596 Cigarette Lighter: Connector Views Connector View C2031a Connector View C2031b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9597 Cigarette Lighter: Electrical Diagrams Diagram 44-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9598 Diagram 44-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service Precautions Compass: Service Precautions CAUTION: During demagnetizing, the demagnetizer coil will be pulled toward the vehicle. Place a cloth over the vehicle roof to protect the vehicle surface if contact occurs. Make sure the cloth covers the front third and the entire width of the roof. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service Precautions > Page 9602 Compass: Description and Operation A compass and outside temperature display are contained in the overhead console. The compass and temperature display can be turned off and on by pressing the MODE switch in the overhead console. The vehicle heading is displayed as one of N, NE, E, SE, S, SW, W, and NW. Compass Accuracy Magnetic mounted devices like antennas and luggage racks should not be located on the front third of the vehicle roof. Placing these devices near the compass will cause inaccurate directional readings. If these devices must be used, accuracy may be improved by recalibrating the compass while the devices are installed on the vehicle. Driving near power lines, or driving in the area of large iron or steel structures can temporarily change the compass heading. If the compass remains inaccurate after driving near such objects, demagnetize the vehicle and recalibrate the compass. Most geographic areas (zones) have a magnetic north compass point that varies slightly from the northerly direction on maps. This variation is four degrees between the adjacent zones and will become noticeable as the vehicle crosses multiple zones. A correct zone setting eliminates the error. Refer to Compass Zone Adjustment. Temperature, Outside Air The thermometer sensor is attached to the radiator frame behind the grille. The temperature can be displayed in Celsius or Fahrenheit by pressing the MODE switch. If the outside temperature falls below 3.3°C (38°F), the display will alternate from ICE to the outside temperature at a two-second rate for one minute. The outside air temperature reading can be affected by engine heat when the vehicle is idling or has been off for less than two hours. The compass and thermometer will limit the increase of the displayed temperature to one degree per minute at very low speeds or immediately after the ignition is turned on. After two minutes at a sustained speed of at least 53 km/h (33 mph), effects of engine heat are minimal and the compass will display the current outside temperature reading. Temperature decreases are always updated immediately. If the outside air temperature sensor is short circuited or open, the display will show 60°C (140°F) or -40°C (-40°F) respectively in place of temperature. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Compass: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the electronic compass. Visual Inspection Chart 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If inspection reveals an obvious concern(s) that can be readily identified, repair or install a new component as necessary. 4. If the fault is not visually evident, determine the symptom and proceed to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9605 Symptom Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9606 Compass: Pinpoint Tests Connector Circuit Reference Refer to Vehicle/Diagrams for schematic and connector information. Pinpoint Test Notes NOTE: - Always set the zone, calibrate, and demagnetize a vehicle before installing a new electronic compass module. - After installing a new electronic compass module, always set the zone and calibrate. Test A: Compass Is Inaccurate/Inoperative A1 - A2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9607 A3 - A4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9608 A5 - A6 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9609 A7 - A8 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9610 A9 - A10 Test B: Outside Air Temperature Is Inaccurate/Inoperative Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9611 B1 - B3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9612 B3 - B5 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9613 B5 - B6 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9614 73III Automotive Meter Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Compass Zone Adjustment Compass: Adjustments Compass Zone Adjustment 1. Determine the zone in which the vehicle is located. 2. Press and hold the MODE button until VAR appears on the display. Release the MODE button. 3. Momentarily press the MODE button to increment the zone by one. Set the zone according to the map. NOTE: After a few seconds, the compass will exit the VAR mode if the button is no longer pressed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Compass Zone Adjustment > Page 9617 Compass: Adjustments Compass Calibration 1. Start the vehicle. NOTE: For optimum calibration, drive to an open, level location away from large metallic objects or structures. Switch off all non-essential electrical accessories (rear window defrost, heater A/C, map lamps, wipers, etc.) and make sure all doors are closed. 2. Locate the electronic compass/temperature display on the overhead console, press and hold the MODE button until CAL appears in the display, then release the MODE button. NOTE: To exit CAL mode before carrying out a compass adjustment, turn the ignition switch to the OFF position. 3. Drive the vehicle slowly (less than 5 km/h [3 mph]) in complete circles until CAL disappears from the display. NOTE: If the CAL indicator does not turn off after the vehicle has been driven in a circle no more than five times, demagnetize the vehicle and repeat the procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > General Procedures Compass: Service and Repair General Procedures CAUTION: During demagnetizing, the demagnetizer coil will be pulled toward the vehicle. Place a cloth over the vehicle roof to protect the vehicle surface if contact occurs. Make sure the cloth covers the front third and the entire width of the roof. NOTE: - The demagnetizing process requires the use of a demagnetizing coil commonly used by television repair technicians to demagnetize television tubes. - To demagnetize, use a constant circular motion over the vehicle roof. Do not turn off the demagnetizer while sweeping the vehicle roof to prevent remagnetizing ferrous materials contained in the vehicle. - During the demagnetizing process, make sure the phenolic surface of the tool (the side opposite the handle) is closest to the vehicle surface. 1. Demagnetize the front third of the vehicle roof. 1 Turn on the demagnetizer at least 1 m (3 ft) away from the vehicle. 2 Holding the demagnetizer no more than 2.5 cm (1 in) from the vehicle roof and starting on the passenger side, demagnetize the front third of the vehicle roof closest to the windshield using a constant circular motion. Keep the circle radius within 30 cm (12 in) while sweeping across the entire surface of the vehicle roof closest to the windshield. Continue the circular motion four times. 3 After the fourth pass and without stopping, move the demagnetizer at least 1 m (3 ft) away from the vehicle. 4 Turn the demagnetizer off. 2. Carry out the Compass Zone Adjustment procedure. 3. Carry out the Compass Calibration Adjustment procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > General Procedures > Page 9620 Compass: Service and Repair Removal and Installation Compass Module - Electronic With Storage Console REMOVAL 1. Remove the overhead console. 2. Remove the screws. 3. Push the latch and remove the compass/lamp bezel from the console housing. 4. Disconnect the harness connector and remove the switches and the harness from the compass module. INSTALLATION 1. To install, reverse the removal procedure. Compass Module - Electronic With Moonroof REMOVAL 1. Remove the overhead console. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > General Procedures > Page 9621 2. Remove the screws. 3. Disconnect the harness connector and remove the switches and the harness from the compass module. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Page 9622 73III Automotive Meter Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Customer Safety Information Air Bag(s) Arming and Disarming: Customer Safety Information WARNING: ^ IF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS BEING SERVICED, THE SYSTEM MUST BE DEACTIVATED AND RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED. ^ THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, TURN THE IGNITION OFF AND DISCONNECT THE BATTERY GROUND CABLE, WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Customer Safety Information > Page 9628 Air Bag(s) Arming and Disarming: Technician Safety Information WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, CAUTIONS, AND NOTES AT THE BEGINNING OF THE DEACTIVATION PROCEDURE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Customer Safety Information > Page 9629 Air Bag(s) Arming and Disarming: Vehicle Damage Warnings CAUTION: ^ Do not handle the passenger air bag module by grabbing the edges of the deployment door. ^ Do not deactivate the side air bag module circuit be removing the side air bag bridge resistor from the side air bag to floor connector. ^ If the side air bag bridge resistor is removed, an open circuit fault will be generated by the Restraints Control Module (RCM). ^ If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Deactivation Procedure Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will This will reduce the risk of injury in the event of an accidental deployment. WARNING: To reduce the risk of personal injury, do not use any memory saver devices. NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood connected. WARNING: To reduce the risk of personal injury, do not use any memory saver devices. NOTE: The air bag warning lamp illuminates when the RGM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9632 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, See: Starting and Charging/Battery 7. Remove the two steering wheel back cover plugs. 8. Remove the driver air bag module retaining bolts. 9. Remove the driver air bag module. 1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9633 10. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector at the top of the steering column. 11. Open the glove compartment door past its stops to access the mounting screws. 12. Remove the two screws. 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Reaching one hand into the glove compartment opening push out on the passenger air bag module and separate it from the instrument panel. Note the wire harness routing for installation. 14. Disconnect the electrical connector and remove the passenger air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9634 15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. Vehicles without seat side air bags 16. CAUTION: Do not deactivate the side air bag module circuit be removing the side air bag bridge resistor from the side air bag to floor connector. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM). If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. Vehicles with seat side air bags and power driver seat 17. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. For additional information, See: Starting and Charging/Battery Vehicles with seat side air bags 18. Move and tilt the front seats to their highest and most forward position. Vehicles with seat side air bags and power driver seat 19. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, See: Starting and Charging/Battery Vehicles with seat side air bags 20. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector. 21. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9635 22. Remove the tie-strap and disconnect the driver seat side air bag electrical connector. 23. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. All vehicles 24. Install the RCM fuse F2.6 (7.5A without rear blower, 15A with rear blower) to the CJB and close the cover. 25. Connect the battery ground cable. For additional See: Starting and Charging/Battery Reactivation Procedure Reactivation All vehicles 1. Turn the ignition switch to OFF. 2. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For additional information, refer to the wiring Diagram Manual. 3. Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, See: Starting and Charging/Battery Vehicles with seat side air bags 4. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9636 5. Connect the driver seat side air bag electrical connector and tie-strap the wire harness. 6. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical connector. 7. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. Vehicles with seat side air bags and power driver seat 8. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. For additional information, See: Starting and Charging/Battery Vehicles with seat side air bags 9. Position the front seats rearward. Vehicles with seat side air bags and power driver seat 10. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, refer to See: Starting and Charging/Battery All vehicles Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9637 11. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. 12. Position the passenger air bag module to the instrument panel (I/P) and connect the electrical connector. 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Position the passenger air bag module into the instrument panel. Route the wire harness as noted in removal. 14. Install the two screws. 15. Close the glove compartment door. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9638 16. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector at the top of the steering column. 17. Position the driver air bag module to the steering wheel. 1. Connect the driver air bag module electrical connector. 2. Position the driver air bag module to the steering wheel. 18. Install the two driver air bag module retaining bolts. 19. Install the two steering wheel back cover plugs. 20. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 21. Turn the ignition switch from OFF to ON. 22. Install the RCM fuse F2.6 (7.5A without rear blower, 15A with rear blower) to the CJB and close the cover. 23. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9639 Connect the battery ground cable. 24. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: -fail to light. -remain lit continuously. -flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. 25. Clear all continuous DTCs from the restraints control module using a scan tool. Seats Removed There are two deactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. WARNING: IF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS BEING SERVICED, THE SYSTEM MUST BE DEACTIVATED AND RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED. THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. NOTE: ^ Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Disconnect the battery ground cable. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the driver air bag module. 4. Attach a Restraint System Diagnostic Tool 418-F088 (105-R0012) to the clockspring side of the driver air bag module connector. 5. Remove the passenger air bag module. 6. Attach a Restraint System Diagnostic Tool 418-F088 (105-R0012) to the vehicle harness side of the passenger air bag connector. 7. If equipped with a front power driver seat, reconnect the battery ground cable. 8. Move and tilt the front seats to their highest and most forward position. 9. If equipped with a front power driver seat, disconnect the battery ground cable. 10. Remove the affected front seat(s). 11. Disconnect the passenger seat side air bag module electrical connector (if necessary) and attach Restraint System Diagnostic Tool 418-133 (40-009) to the vehicle harness side of the passenger seat side air bag module electrical connector. 12. Disconnect the driver seat side air bag module electrical connector (if necessary) and attach Restraint System Diagnostic Tool 418-133 (40-009) to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9640 the vehicle harness side of the driver seat side air bag module electrical connector. 13. Reconnect the battery ground cable. Seats Not Removed There are two deactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. WARNING: IF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS BEING SERVICED, THE SYSTEM MUST BE DEACTIVATED AND RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED. THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. NOTE: ^ Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Disconnect the battery ground cable. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the driver air bag module. 4. Attach a Restraint System Diagnostic Tool 418-F088 (105-R0012) to the clockspring side of the driver air bag module connector. 5. Remove the passenger air bag module. 6. Attach a Restraint System Diagnostic Tool 418-F088 (105-R0012) to the vehicle harness side of the passenger air bag connector. 7. If equipped with seat side air bags and a front power driver seat reconnect the battery ground cable. 8. Move and tilt the front seats to their highest and most forward position. 9. If equipped with seat side air bags and a front power driver seat, disconnect the battery ground cable. 10. If equipped with seat side air bags, disconnect the passenger seat side air bag module electrical connector and attach Restraint System Diagnostic Tool 418-133 (40-009) to the vehicle harness side of the passenger seat side air bag module electrical connector. CAUTION: Vehicles without side air bags, do not deactivate the side air bag module circuit by removing the side air bag bridge resistor from the side air bag floor connector. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM). If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. 11. If equipped with seat side air bags, disconnect the driver seat side air bag module electrical connector and attach Restraint System Diagnostic Tool 418-133 (40-009) to the vehicle harness side of the driver seat side air bag module electrical connector. CAUTION: Vehicles without side air bags, do not deactivate the side air bag module circuit by removing the side air bag bridge resistor from the side air bag floor connector. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9641 If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. 12. Reconnect the battery ground cable. Seats Removed There are two reactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES AND PRETENSIONERS MUST BE RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. 1. Move and tilt the front seats to their highest and most forward position. 2. Disconnect the battery ground cable. 3. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 4. Remove the restraint system diagnostic tool from the driver seat side air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. Remove the restraint system diagnostic tool from the passenger seat side air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 6. Install the affected front seat(s). 7. Connect the driver seat side air bag module electrical connectors. 8. Connect the passenger seat side air bag module electrical connectors. 9. If equipped with a front power driver seat, reconnect the battery ground cable. 10. Move the front seats rearward. 11. If equipped with a front power driver seat, disconnect the battery ground cable. 12. Remove the restraint system diagnostic tool from the passenger air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 13. Install the passenger air bag module. 14. Remove the restraint system diagnostic tool from the clockspring connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 15. Install the driver air bag module. 16. Reconnect the battery ground cable. 17. Prove out the system. Seats Not Removed There are two reactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES AND Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9642 PRETENSIONERS MUST BE RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. 1. If equipped with seat side air bags, move and tilt the front seats to their highest and most forward position. 2. Disconnect the battery ground cable. 3. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 4. If equipped with seat side air bags: 1 Remove the restraint system diagnostic tool from the driver seat side air bag module electrical connector. 2 Remove the restraint system diagnostic tool from the passenger seat side air bag module electrical connector. 3 Connect the driver seat side air bag module electrical connectors. 4 Connect the passenger seat side air bag module electrical connectors. 5 Reconnect the battery ground cable. 6 Move the front seats rearward. 7 Disconnect the battery ground cable. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. Remove the restraint system diagnostic tool from the passenger air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 6. Install the passenger air bag module. 7. Remove the restraint system diagnostic tool from the clockspring connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 8. Install the driver air bag module. 9. Reconnect the battery ground cable. 10. Prove out the system. Procedures For Repair Operations SPECIAL TOOL(S) DEACTIVATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9643 INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the air bag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the seat side air bag (if equipped) and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Remove the retaining screws and position the hood release handle out of the way. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9644 3. Remove the lower steering column opening finish panel. 1 Remove the two retaining screws from the lower steering column opening finish panel. 2 Pull out to release the retaining clips and remove the lower steering column opening finish panel. 4. Remove the bolts and the lower steering column opening finish panel reinforcement. 5. Disconnect the clockspring electrical connector at the base of the steering column. 6. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9645 7. Open the glove compartment door past its stops to access the mounting screws. 8. Remove the two screws. 9. Reaching one hand into the glove compartment opening, push out on the passenger air bag module and separate it from the instrument panel. Note the wire harness routing for installation. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. 10. Disconnect the electrical connector and remove the passenger air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9646 11. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. Vehicles without seat side air bags 12. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the Restraints Control Module (RCM). If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. CAUTION: Do not deactivate the side air bag module circuit be removing the side air bag bridge resistor from the side air bag to floor connector. Vehicles with seat side air bags and power driver seat 13. Connect the battery ground cable. Vehicles with seat side air bags 14. Move and tilt the front seats to their highest and most forward position. Vehicles with seat side air bags and power driver seat 15. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Vehicles with seat side air bags 16. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9647 17. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. 18. Remove the tie-strap and disconnect the driver seat side air bag electrical connector. 19. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. All vehicles 20. Connect the battery ground cable. 21. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). See: Prove Out Procedure 22. Disconnect the battery ground cable and wait at least one minute. REACTIVATION WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, CAUTIONS, AND NOTES AT THE BEGINNING OF THE DEACTIVATION PROCEDURE. Vehicles with seat side air bags Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9648 1. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical connector. NOTE: Make sure the battery ground cable is still disconnected before proceeding with the reactivation portion of this procedure. 2. Connect the driver seat side air bag electrical connector and tie-strap the wire harness. 3. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical connector. 4. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. Vehicles with seat side air bags and power driver seat 5. Connect the battery ground cable. Vehicles with seat side air bags 6. Position the front seats rearward. Vehicles with seat side air bags and power driver seat Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9649 7. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). All vehicles 8. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. 9. Position the passenger air bag module to the Instrument Panel (I/P) and connect the electrical connector. 10. Position the passenger air bag module into the instrument panel. Route the wire harness as noted in removal. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9650 11. In stall the two screws. 12. Close the glove compartment door. 13. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector at the base of the steering column. 14. Connect the clockspring electrical connector at the base of the steering column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9651 15. Position the lower steering column opening finish panel reinforcement and install the bolts. 16. Install the lower steering column opening finish panel. 1 Position the lower steering column opening finish panel to the I/P and push in at the top to seat the retaining clips. 2 Install the screws. 17. Position the hood release handle and install the screws. 18. Connect the battery ground cable. 19. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Prove Out Procedure WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 20. Check the active restraint system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9652 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag modules connected? 3. Is the Restraints Control Module (RCM) connected? 4. Is the vehicle battery connected? Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9653 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure Turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator with the air bag modules or restraint system diagnostic tools installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag Supplemental Restraint System (SRS) fault is present, the air bag indicator will either: ^ fail to light. ^ remain lit continuously. ^ flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the RUN position. This is the time required for the Restraints Control Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Page 9654 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Left Connector View C458 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Left > Page 9659 Connector View C459 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Left > Page 9660 Door Switch: Diagrams Driver Side Front Connector View C526a Connector View C526b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Left > Page 9661 Door Switch: Diagrams Driver Side Rear Connector View C715a Connector View C715b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Left > Page 9662 Door Switch: Diagrams Connector View C458 Connector View C459 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Left > Page 9663 Connector View C526a Connector View C526b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Left > Page 9664 Connector View C715a Connector View C715b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Left > Page 9665 Connector View C602a Connector View C602b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Left > Page 9666 Connector View C820a Connector View C820b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Service and Repair > Door Ajar Switch Door Switch: Service and Repair Door Ajar Switch REMOVAL 1. Remove the door interior trim panel. NOTE: Front door shown, rear door similar. 2. Position the watershield aside. 3. Disconnect the ground wire and remove the screw. 4. Remove the door ajar switch. - Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Service and Repair > Door Ajar Switch > Page 9669 Door Switch: Service and Repair Door Ajar Switch - Liftgate REMOVAL 1. Remove the liftgate latch. 2. Remove the liftgate latch ajar switch. - Remove the screw. INSTALLATION 1. To install, reverse the removal process. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Customer Safety Information Air Bag(s) Arming and Disarming: Customer Safety Information WARNING: ^ IF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS BEING SERVICED, THE SYSTEM MUST BE DEACTIVATED AND RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED. ^ THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, TURN THE IGNITION OFF AND DISCONNECT THE BATTERY GROUND CABLE, WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Customer Safety Information > Page 9675 Air Bag(s) Arming and Disarming: Technician Safety Information WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, CAUTIONS, AND NOTES AT THE BEGINNING OF THE DEACTIVATION PROCEDURE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service Precautions > Customer Safety Information > Page 9676 Air Bag(s) Arming and Disarming: Vehicle Damage Warnings CAUTION: ^ Do not handle the passenger air bag module by grabbing the edges of the deployment door. ^ Do not deactivate the side air bag module circuit be removing the side air bag bridge resistor from the side air bag to floor connector. ^ If the side air bag bridge resistor is removed, an open circuit fault will be generated by the Restraints Control Module (RCM). ^ If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Deactivation Procedure Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will This will reduce the risk of injury in the event of an accidental deployment. WARNING: To reduce the risk of personal injury, do not use any memory saver devices. NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood connected. WARNING: To reduce the risk of personal injury, do not use any memory saver devices. NOTE: The air bag warning lamp illuminates when the RGM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9679 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, See: Starting and Charging/Battery 7. Remove the two steering wheel back cover plugs. 8. Remove the driver air bag module retaining bolts. 9. Remove the driver air bag module. 1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9680 10. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector at the top of the steering column. 11. Open the glove compartment door past its stops to access the mounting screws. 12. Remove the two screws. 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Reaching one hand into the glove compartment opening push out on the passenger air bag module and separate it from the instrument panel. Note the wire harness routing for installation. 14. Disconnect the electrical connector and remove the passenger air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9681 15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. Vehicles without seat side air bags 16. CAUTION: Do not deactivate the side air bag module circuit be removing the side air bag bridge resistor from the side air bag to floor connector. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM). If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. Vehicles with seat side air bags and power driver seat 17. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. For additional information, See: Starting and Charging/Battery Vehicles with seat side air bags 18. Move and tilt the front seats to their highest and most forward position. Vehicles with seat side air bags and power driver seat 19. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, See: Starting and Charging/Battery Vehicles with seat side air bags 20. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector. 21. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9682 22. Remove the tie-strap and disconnect the driver seat side air bag electrical connector. 23. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. All vehicles 24. Install the RCM fuse F2.6 (7.5A without rear blower, 15A with rear blower) to the CJB and close the cover. 25. Connect the battery ground cable. For additional See: Starting and Charging/Battery Reactivation Procedure Reactivation All vehicles 1. Turn the ignition switch to OFF. 2. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2.6 (7.5A without rear blower, 15A with rear blower) from the CJB. For additional information, refer to the wiring Diagram Manual. 3. Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, See: Starting and Charging/Battery Vehicles with seat side air bags 4. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9683 5. Connect the driver seat side air bag electrical connector and tie-strap the wire harness. 6. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical connector. 7. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. Vehicles with seat side air bags and power driver seat 8. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. For additional information, See: Starting and Charging/Battery Vehicles with seat side air bags 9. Position the front seats rearward. Vehicles with seat side air bags and power driver seat 10. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, refer to See: Starting and Charging/Battery All vehicles Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9684 11. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. 12. Position the passenger air bag module to the instrument panel (I/P) and connect the electrical connector. 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Position the passenger air bag module into the instrument panel. Route the wire harness as noted in removal. 14. Install the two screws. 15. Close the glove compartment door. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9685 16. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector at the top of the steering column. 17. Position the driver air bag module to the steering wheel. 1. Connect the driver air bag module electrical connector. 2. Position the driver air bag module to the steering wheel. 18. Install the two driver air bag module retaining bolts. 19. Install the two steering wheel back cover plugs. 20. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 21. Turn the ignition switch from OFF to ON. 22. Install the RCM fuse F2.6 (7.5A without rear blower, 15A with rear blower) to the CJB and close the cover. 23. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9686 Connect the battery ground cable. 24. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: -fail to light. -remain lit continuously. -flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. 25. Clear all continuous DTCs from the restraints control module using a scan tool. Seats Removed There are two deactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. WARNING: IF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS BEING SERVICED, THE SYSTEM MUST BE DEACTIVATED AND RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED. THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. NOTE: ^ Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Disconnect the battery ground cable. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the driver air bag module. 4. Attach a Restraint System Diagnostic Tool 418-F088 (105-R0012) to the clockspring side of the driver air bag module connector. 5. Remove the passenger air bag module. 6. Attach a Restraint System Diagnostic Tool 418-F088 (105-R0012) to the vehicle harness side of the passenger air bag connector. 7. If equipped with a front power driver seat, reconnect the battery ground cable. 8. Move and tilt the front seats to their highest and most forward position. 9. If equipped with a front power driver seat, disconnect the battery ground cable. 10. Remove the affected front seat(s). 11. Disconnect the passenger seat side air bag module electrical connector (if necessary) and attach Restraint System Diagnostic Tool 418-133 (40-009) to the vehicle harness side of the passenger seat side air bag module electrical connector. 12. Disconnect the driver seat side air bag module electrical connector (if necessary) and attach Restraint System Diagnostic Tool 418-133 (40-009) to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9687 the vehicle harness side of the driver seat side air bag module electrical connector. 13. Reconnect the battery ground cable. Seats Not Removed There are two deactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. WARNING: IF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS BEING SERVICED, THE SYSTEM MUST BE DEACTIVATED AND RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE INSTALLED. THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. NOTE: ^ Diagnostics or repairs are not to be performed on a seat equipped with a seat side airbag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side airbag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Disconnect the battery ground cable. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the driver air bag module. 4. Attach a Restraint System Diagnostic Tool 418-F088 (105-R0012) to the clockspring side of the driver air bag module connector. 5. Remove the passenger air bag module. 6. Attach a Restraint System Diagnostic Tool 418-F088 (105-R0012) to the vehicle harness side of the passenger air bag connector. 7. If equipped with seat side air bags and a front power driver seat reconnect the battery ground cable. 8. Move and tilt the front seats to their highest and most forward position. 9. If equipped with seat side air bags and a front power driver seat, disconnect the battery ground cable. 10. If equipped with seat side air bags, disconnect the passenger seat side air bag module electrical connector and attach Restraint System Diagnostic Tool 418-133 (40-009) to the vehicle harness side of the passenger seat side air bag module electrical connector. CAUTION: Vehicles without side air bags, do not deactivate the side air bag module circuit by removing the side air bag bridge resistor from the side air bag floor connector. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM). If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. 11. If equipped with seat side air bags, disconnect the driver seat side air bag module electrical connector and attach Restraint System Diagnostic Tool 418-133 (40-009) to the vehicle harness side of the driver seat side air bag module electrical connector. CAUTION: Vehicles without side air bags, do not deactivate the side air bag module circuit by removing the side air bag bridge resistor from the side air bag floor connector. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM). Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9688 If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. 12. Reconnect the battery ground cable. Seats Removed There are two reactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES AND PRETENSIONERS MUST BE RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. 1. Move and tilt the front seats to their highest and most forward position. 2. Disconnect the battery ground cable. 3. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 4. Remove the restraint system diagnostic tool from the driver seat side air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. Remove the restraint system diagnostic tool from the passenger seat side air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 6. Install the affected front seat(s). 7. Connect the driver seat side air bag module electrical connectors. 8. Connect the passenger seat side air bag module electrical connectors. 9. If equipped with a front power driver seat, reconnect the battery ground cable. 10. Move the front seats rearward. 11. If equipped with a front power driver seat, disconnect the battery ground cable. 12. Remove the restraint system diagnostic tool from the passenger air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 13. Install the passenger air bag module. 14. Remove the restraint system diagnostic tool from the clockspring connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 15. Install the driver air bag module. 16. Reconnect the battery ground cable. 17. Prove out the system. Seats Not Removed There are two reactivation procedures. ^ One procedure requires removal of the front seats. This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat-mounted component of a seat equipped with a seat side air bag. The seat must be removed when performing repairs on a seat equipped with a seat side air bag. ^ The other procedure does not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. WARNING: THE AIR BAG RESTRAINT SYSTEM DIAGNOSTIC TOOLS MUST BE REMOVED AND THE AIR BAG MODULES AND Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9689 PRETENSIONERS MUST BE RECONNECTED WHEN THE SYSTEM IS REACTIVATED TO AVOID NON-DEPLOYMENT IN A COLLISION, RESULTING IN POSSIBLE PERSONAL INJURY. 1. If equipped with seat side air bags, move and tilt the front seats to their highest and most forward position. 2. Disconnect the battery ground cable. 3. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 4. If equipped with seat side air bags: 1 Remove the restraint system diagnostic tool from the driver seat side air bag module electrical connector. 2 Remove the restraint system diagnostic tool from the passenger seat side air bag module electrical connector. 3 Connect the driver seat side air bag module electrical connectors. 4 Connect the passenger seat side air bag module electrical connectors. 5 Reconnect the battery ground cable. 6 Move the front seats rearward. 7 Disconnect the battery ground cable. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. Remove the restraint system diagnostic tool from the passenger air bag module electrical connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 6. Install the passenger air bag module. 7. Remove the restraint system diagnostic tool from the clockspring connector. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 8. Install the driver air bag module. 9. Reconnect the battery ground cable. 10. Prove out the system. Procedures For Repair Operations SPECIAL TOOL(S) DEACTIVATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9690 INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the air bag system must be deactivated. ^ Restraint system diagnostic tools MUST be installed under the seats in the seat side air bag (if equipped) and safety belt pretensioner (if equipped) to floor connectors. ^ Diagnostics or repairs are not to be performed on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. ^ After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. ^ The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 2. Remove the retaining screws and position the hood release handle out of the way. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9691 3. Remove the lower steering column opening finish panel. 1 Remove the two retaining screws from the lower steering column opening finish panel. 2 Pull out to release the retaining clips and remove the lower steering column opening finish panel. 4. Remove the bolts and the lower steering column opening finish panel reinforcement. 5. Disconnect the clockspring electrical connector at the base of the steering column. 6. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9692 7. Open the glove compartment door past its stops to access the mounting screws. 8. Remove the two screws. 9. Reaching one hand into the glove compartment opening, push out on the passenger air bag module and separate it from the instrument panel. Note the wire harness routing for installation. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. 10. Disconnect the electrical connector and remove the passenger air bag module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9693 11. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. Vehicles without seat side air bags 12. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the Restraints Control Module (RCM). If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. CAUTION: Do not deactivate the side air bag module circuit be removing the side air bag bridge resistor from the side air bag to floor connector. Vehicles with seat side air bags and power driver seat 13. Connect the battery ground cable. Vehicles with seat side air bags 14. Move and tilt the front seats to their highest and most forward position. Vehicles with seat side air bags and power driver seat 15. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). Vehicles with seat side air bags 16. Remove the tie-strap and disconnect the passenger seat side air bag electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9694 17. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. 18. Remove the tie-strap and disconnect the driver seat side air bag electrical connector. 19. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. All vehicles 20. Connect the battery ground cable. 21. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). See: Prove Out Procedure 22. Disconnect the battery ground cable and wait at least one minute. REACTIVATION WARNING: TO REDUCE THE RISK OF SERIOUS PERSONAL INJURY, READ AND FOLLOW ALL WARNINGS, CAUTIONS, AND NOTES AT THE BEGINNING OF THE DEACTIVATION PROCEDURE. Vehicles with seat side air bags Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9695 1. Remove the restraint system diagnostic tool from the driver seat side air bag floor electrical connector. NOTE: Make sure the battery ground cable is still disconnected before proceeding with the reactivation portion of this procedure. 2. Connect the driver seat side air bag electrical connector and tie-strap the wire harness. 3. Remove the restraint system diagnostic tool from the passenger seat side air bag floor electrical connector. 4. Connect the passenger seat side air bag electrical connector and tie-strap the wire harness. Vehicles with seat side air bags and power driver seat 5. Connect the battery ground cable. Vehicles with seat side air bags 6. Position the front seats rearward. Vehicles with seat side air bags and power driver seat Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9696 7. Disconnect the battery ground cable and wait at least one minute. WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). All vehicles 8. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. 9. Position the passenger air bag module to the Instrument Panel (I/P) and connect the electrical connector. 10. Position the passenger air bag module into the instrument panel. Route the wire harness as noted in removal. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9697 11. In stall the two screws. 12. Close the glove compartment door. 13. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector at the base of the steering column. 14. Connect the clockspring electrical connector at the base of the steering column. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9698 15. Position the lower steering column opening finish panel reinforcement and install the bolts. 16. Install the lower steering column opening finish panel. 1 Position the lower steering column opening finish panel to the I/P and push in at the top to seat the retaining clips. 2 Install the screws. 17. Position the hood release handle and install the screws. 18. Connect the battery ground cable. 19. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Prove Out Procedure WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 20. Check the active restraint system for correct operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9699 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag modules connected? 3. Is the Restraints Control Module (RCM) connected? 4. Is the vehicle battery connected? Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9700 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure Turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator with the air bag modules or restraint system diagnostic tools installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag Supplemental Restraint System (SRS) fault is present, the air bag indicator will either: ^ fail to light. ^ remain lit continuously. ^ flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the RUN position. This is the time required for the Restraints Control Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Page 9701 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Service and Repair Instrument Panel Bulb: Service and Repair REMOVAL WARNING: ILLUMINATION BULBS ARE PRESSURIZED AND MAY SHATTER IF INCORRECTLY HANDLED. WEAR EYE PROTECTION WHEN INSTALLING NEW ILLUMINATION BULBS. 1. Remove the instrument cluster. 2. Remove the illumination sockets and bulbs. 3. Remove the indicator sockets and bulbs. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Circuit Board > Component Information > Service and Repair Instrument Panel Circuit Board: Service and Repair REMOVAL WARNING: ILLUMINATION BULBS ARE PRESSURIZED AND MAY SHATTER IF INCORRECTLY HANDLED. WEAR EYE PROTECTION WHEN INSTALLING NEW BULBS. CAUTION: If gauges are being removed from the cluster assembly, do not remove the gauge pointers. Magnetic gauges cannot be recalibrated. 1. Remove the instrument cluster. 2. Remove the illumination and indicator bulbs. 3. Remove the gauges. 4. Remove the 19 instrument gauge clips. NOTE: New gauge clips must be used for assembly. 5. Remove the instrument cluster printed circuit. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 9716 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 9717 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 9718 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 9724 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 9725 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 9726 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Panel Illumination Control Module > Component Information > Locations View 151-9 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Panel Illumination Control Module > Component Information > Locations > Page 9730 Panel Illumination Control Module: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Panel Illumination Control Module > Component Information > Locations > Page 9731 Instrument Panel Dimming Module, Interior Lamps Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation Malfunction Indicator Lamp (MIL) Check Engine, Service Engine Soon Or ISO Standard Engine Symbol The Malfunction Indicator Lamp (MIL) (Figure 15) alerts the driver that the Powertrain Control Module (PCM) has detected an On Board Diagnostic (OBD) II emission-related component or system fault. When this occurs, an OBD II Diagnostic Trouble Code (DTC) will be set. - The MIL is located on the instrument cluster and is labeled CHECK ENGINE, SERVICE ENGINE SOON or ISO standard engine symbol (Figure 16). - Power is supplied to the MIL whenever the ignition switch is in the RUN or START position. - The MIL will remain on in the RUN/START mode as a bulb check during the instrument cluster proveout for approximately 4 seconds. - If the MIL remains on after the bulb check: The PCM illuminates the MIL for an emission related concern and a DTC will be present. - The instrument cluster will illuminate the MIL if the PCM does not send a control message to the instrument cluster. - The PCM is operating in the Hardware Limited Operation Strategy (HLOS). - The MIL circuit is shorted to ground. - If the MIL remains off (during the bulb check); Bulb is damaged. - MIL circuit is open. - To turn off the MIL after a repair, a reset command from the Scan Tool must be sent, or three consecutive drive cycles must be completed without a fault. - For any MIL concern, go to Symptom Charts. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Reading Diagnostic Trouble Codes/Performance Diagnostic Procedures/Quick Test - If the MIL blinks at a steady rate, a severe misfire condition could possibly exist. - If the MIL blinks erratically, an intermittent open B+ to the bulb or an intermittent short to ground in the MIL circuit exist. Also, the PCM can reset while cranking if battery voltage is low. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair Oil Change Reminder Lamp: Service and Repair The manufacturer does NOT show that this vehicle is equipped with an oil change reminder lamp. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams Connector View C103 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Diagrams Connector View C2015 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Application and ID Audible Warning Device Control Module: Application and ID For further information please see Accessories and Optional Equipment, General Module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 9756 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 9757 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 9758 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 9764 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 9765 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 9766 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Panel Illumination Control Module > Component Information > Locations View 151-9 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Panel Illumination Control Module > Component Information > Locations > Page 9770 Panel Illumination Control Module: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Panel Illumination Control Module > Component Information > Locations > Page 9771 Instrument Panel Dimming Module, Interior Lamps Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Description and Operation Seat Belt Reminder Lamp: Description and Operation Safety Belt Warning Indicator and Chime The warning indicator and chime are reminders to fasten the safety belt. The following conditions will take place: If the safety belt is not buckled before the ignition is turned to the ON position, the chime will turn on for four to eight seconds and the indicator will come on for one to two minutes. - If the safety belt is buckled while the indicator is on and the chime is sounding, both the indicator and chime will turn off. - If the safety belt is buckled before the ignition is turned to the ON position, neither the indicator nor the chime will turn on. Belt Minder (if equipped) The Belt Minder feature is a supplemental warning to the safety belt warning function. This feature provides additional reminders to the driver that the driver's safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning lamp in the instrument cluster. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Left Connector View C458 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Left > Page 9780 Connector View C459 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Left > Page 9781 Door Switch: Diagrams Driver Side Front Connector View C526a Connector View C526b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Left > Page 9782 Door Switch: Diagrams Driver Side Rear Connector View C715a Connector View C715b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Left > Page 9783 Door Switch: Diagrams Connector View C458 Connector View C459 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Left > Page 9784 Connector View C526a Connector View C526b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Left > Page 9785 Connector View C715a Connector View C715b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Left > Page 9786 Connector View C602a Connector View C602b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Left > Page 9787 Connector View C820a Connector View C820b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Door Ajar Switch Door Switch: Service and Repair Door Ajar Switch REMOVAL 1. Remove the door interior trim panel. NOTE: Front door shown, rear door similar. 2. Position the watershield aside. 3. Disconnect the ground wire and remove the screw. 4. Remove the door ajar switch. - Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Door Ajar Switch > Page 9790 Door Switch: Service and Repair Door Ajar Switch - Liftgate REMOVAL 1. Remove the liftgate latch. 2. Remove the liftgate latch ajar switch. - Remove the screw. INSTALLATION 1. To install, reverse the removal process. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Diagrams Connector View C2015 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Specifications Temperature Sensor (Gauge): Specifications Engine coolant temperature (ECT) sensor ............................................................................................................................................ 10 Nm (89 inch lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Specifications > Page 9797 Temperature Sensor (Gauge): Service and Repair Sender Unit-Water Temperature Indicator Removal and Installation 1. Partially drain the cooling system. 2. Remove the thermostat. 3. Disconnect the electrical connector. 4. Remove the water temperature indicator sending unit. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations View 151-16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 9802 Connector View C995 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Reversing Lamp <--> [Backup Lamp] > Backup Lamp Switch > Component Information > Locations View 151-5 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Reversing Lamp <--> [Backup Lamp] > Backup Lamp Switch > Component Information > Diagrams > Digital Transmission Range Sensor Connector View C167 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Reversing Lamp <--> [Backup Lamp] > Backup Lamp Switch > Component Information > Diagrams > Digital Transmission Range Sensor > Page 9809 Connector View C169 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Diagrams Connector View C278 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Description and Operation > Brake Pedal Position Switch Brake Pedal Position Switch: Description and Operation Brake Pedal Position Switch Brake Pedal Position Switch Typical Brake Pedal Position Switch The Brake Pedal Position (BPP) switch (Figure 21) is used by the PCM to disengage the transmission torque converter clutch and on some applications as an input to the idle speed control for idle quality and for vehicle speed control deactivation. On most applications the BPP switch is hard wired to the PCM and supplies battery positive voltage (B+) when the vehicle brake pedal is applied. On other applications the BPP switch signal is broadcast over the SCP link via another module to be received by the PCM. On applications where the BPP switch is hard wired to the PCM and stoplamp circuit, if all stoplamp bulbs are burned out (open), high voltage is present at the PCM due to a pull-up resistor in the PCM. This provides fail-safe operation in the event the circuit to the stoplamp bulbs has failed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Description and Operation > Brake Pedal Position Switch > Page 9815 Brake Pedal Position Switch: Description and Operation Brake Pressure Applied Brake Deactivator Switch Brake Pressure Applied Brake Deactivator Switch The Brake Pressure Applied (BPA) switch also sometimes called the brake deactivator switch for vehicle speed control deactivation. Is a normally closed switch, witch supplies battery positive voltage (B+) to the PCM when the brake pedal is NOT applied. When the brake pedal is depressed, the normally closed switch will open and power is removed from the PCM. On some applications the normally closed BPA switch along with the normally open brake pedal position (BPP) switch are used for a brake rationality test within the PCM. The PCM misfire monitor profile learn function can be disable if a brake switch failure occurs. If one or both brake pedal inputs to the PCM did not change states when they were expected to a diagnostic trouble code P1572 can be set by the PCM strategy. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Description and Operation > Page 9816 Brake Pedal Position Switch: Service and Repair REMOVAL 1. Disconnect the Brake Pedal Position (BPP) switch electrical connector. 2. Remove the BPP switch. 1 Remove the self-locking pin. 2 Remove the spacer. 3 Remove the BPP switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams Connector View C927 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > High Mounted Stoplamp <--> [Center Mounted Brake Lamp] > Component Information > Technical Service Bulletins > Customer Interest for High Mounted Stoplamp: > 02-17-6 > Sep > 02 > A/T Inadvertent Shift Interlock Disabling High Mounted Stoplamp: Customer Interest A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > High Mounted Stoplamp <--> [Center Mounted Brake Lamp] > Component Information > Technical Service Bulletins > Customer Interest for High Mounted Stoplamp: > 02-17-6 > Sep > 02 > A/T Inadvertent Shift Interlock Disabling > Page 9828 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > High Mounted Stoplamp <--> [Center Mounted Brake Lamp] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for High Mounted Stoplamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling High Mounted Stoplamp: All Technical Service Bulletins A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > High Mounted Stoplamp <--> [Center Mounted Brake Lamp] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for High Mounted Stoplamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page 9834 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > High Mounted Stoplamp <--> [Center Mounted Brake Lamp] > Component Information > Technical Service Bulletins > Page 9835 Connector View C904 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams Connector View C2014 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Relay > Component Information > Locations Courtesy Lamp Relay: Locations Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Relay > Component Information > Locations > Page 9843 Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Relay > Component Information > Locations > Page 9844 Connector View C2022 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Relay > Component Information > Locations > Page 9845 Courtesy Lamp Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Relay > Component Information > Locations > Page 9846 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams Connector View C254 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Locations View 151-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Locations > Page 9854 Connector View C1030 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Locations > Page 9855 Daytime Running Lamp Control Unit: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the Daytime Running Lamps (DRL) control module. 1 Disconnect the electrical connector. 2 Remove the bolts. 3 Remove the module. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations Battery Discharge Protection Relay: Locations Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 9859 Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 9860 Connector View C2048 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 9861 Battery Discharge Protection Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 9862 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Left Connector View C458 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Left > Page 9867 Connector View C459 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Left > Page 9868 Door Switch: Diagrams Driver Side Front Connector View C526a Connector View C526b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Left > Page 9869 Door Switch: Diagrams Driver Side Rear Connector View C715a Connector View C715b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Left > Page 9870 Door Switch: Diagrams Connector View C458 Connector View C459 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Left > Page 9871 Connector View C526a Connector View C526b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Left > Page 9872 Connector View C715a Connector View C715b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Left > Page 9873 Connector View C602a Connector View C602b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Left > Page 9874 Connector View C820a Connector View C820b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch Door Switch: Service and Repair Door Ajar Switch REMOVAL 1. Remove the door interior trim panel. NOTE: Front door shown, rear door similar. 2. Position the watershield aside. 3. Disconnect the ground wire and remove the screw. 4. Remove the door ajar switch. - Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch > Page 9877 Door Switch: Service and Repair Door Ajar Switch - Liftgate REMOVAL 1. Remove the liftgate latch. 2. Remove the liftgate latch ajar switch. - Remove the screw. INSTALLATION 1. To install, reverse the removal process. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Fog Lamp Relay Fog/Driving Lamp Relay: Locations Fog Lamp Relay Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Fog Lamp Relay > Page 9883 Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Fog Lamp Relay > Page 9884 Fog/Driving Lamp Relay: Locations Fog Lamp Isolation Relay Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Fog Lamp Relay > Page 9885 Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Fog Lamp Relay Connector View C1007 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Fog Lamp Relay > Page 9888 Connector View C1038 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Page 9889 Fog/Driving Lamp Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Page 9890 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams Connector View C240 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Page 9894 Fog/Driving Lamp Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the instrument panel finish panel. 1 Remove the screws. 2 Remove the center instrument panel finish panel. ^ Disconnect the electrical connectors. 3. Remove the fog lamp switch. 1 Remove the screws. 2 Remove the mounting bezel. 3 Release the two tabs and remove the fog lamp switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams Hazard Warning Switch: Diagrams Connector View C202a Connector View C202b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 9899 Hazard Warning Switch: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 9900 Multifunction Switch, Turn Portion Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 9901 Multifunction Switch, Turn Portion Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service Precautions > Technician Safety Information Headlamp Bulb: Technician Safety Information WARNING: THE HALOGEN BULB CONTAINS GAS UNDER PRESSURE. THE BULB MAY SHATTER IF THE GLASS ENVELOPE IS SCRATCHED OR IF THE BULB IS DROPPED. HANDLE THE BULB CAREFULLY. GRASP THE BULB ONLY BY ITS BASE. AVOID TOUCHING THE GLASS ENVELOPE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service Precautions > Technician Safety Information > Page 9907 Headlamp Bulb: Vehicle Damage Warnings CAUTION: The headlamp bulb should not be removed from the headlamp until just before a new bulb is installed. Removing the bulb for an extended period of time may affect headlamp bulb performance. Contaminants may enter the headlamp where they can settle on the lens and reflector. Never turn the headlamps on with the bulb removed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service Precautions > Page 9908 Headlamp Bulb: Service and Repair REMOVAL WARNING: THE HALOGEN BULB CONTAINS GAS UNDER PRESSURE. THE BULB MAY SHATTER IF THE GLASS ENVELOPE IS SCRATCHED OR IF THE BULB IS DROPPED. HANDLE THE BULB CAREFULLY. GRASP THE BULB ONLY BY ITS BASE. AVOID TOUCHING THE GLASS ENVELOPE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. CAUTION: The headlamp bulb should not be removed from the headlamp until just before a new bulb is installed. Removing the bulb for an extended period of time may affect headlamp bulb performance. Contaminants may enter the headlamp where they can settle on the lens and reflector. Never turn the headlamps on with the bulb removed. 1. Remove the headlamp assembly. 2. Rotate the headlamp bulb retainer counterclockwise and remove. 3. Remove the headlamp bulb. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams Headlamp Dimmer Switch: Diagrams Connector View C202a Connector View C202b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Page 9912 Headlamp Dimmer Switch: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Page 9913 Multifunction Switch, Lamp Portion Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Page 9914 Multifunction Switch, Lamp Portion Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Autolamp Headlamp Relay View 151-8 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Autolamp Headlamp Relay > Page 9919 Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Diagrams > Autolamp Headlamp Relay Connector View C2233 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Diagrams > Autolamp Headlamp Relay > Page 9922 Connector View C2234 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Testing and Inspection > Micro ISO Relay Headlamp Relay: Testing and Inspection Micro ISO Relay Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Testing and Inspection > Micro ISO Relay > Page 9925 Relay - Micro ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Testing and Inspection > Micro ISO Relay > Page 9926 Headlamp Relay: Testing and Inspection Mini ISO Relay Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Testing and Inspection > Micro ISO Relay > Page 9927 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams Connector View C205 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 9931 Main Light Switch: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 9932 Main Light Switch, Exterior Lamps, Illumination Lamps Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 9933 Main Light Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the instrument panel center finish panel. 1 Remove the screws. 2 Remove the instrument panel center finish panel. ^ Disconnect electrical connectors. 3. Remove the hood latch release handle. 1 Remove the screws. 2 Remove the hood latch release handle. 4. Remove the lower instrument panel steering column cover. 1 Remove the screws. 2 Remove the lower instrument panel steering column cover. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 9934 5. Remove the bolts and the lower instrument panel reinforcement. 6. If equipped, position the column gear shift lever out of the way. 7. Position the cluster finish panel aside. 1 Remove the screws. 2 Position the cluster finish panel aside. 8. Remove the cluster finish pane 1 Disconnect the electrical connectors and remove the headlamp switch knob. 2 Remove the cluster finish panel. 9. Remove the headlamp switch. 1 Remove the screws. 2 Remove the headlamp switch. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 9935 INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Horn Relay: Locations Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 9940 Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 9941 Connector View C1006 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 9942 Horn Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 9943 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Service and Repair Horn Switch: Service and Repair REMOVAL 1. Remove the driver side air bag. 2. Remove the switch. 1 Disconnect the horn wire (BK) from the switches. 2 Remove the screws and the switch. INSTALLATION 3. To install, reverse the removal procedure. ^ Prove out the air bag system; refer to Air Bag Systems. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Auxiliary Relay Box 2 Relay ID - Before 2/18/02 Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Auxiliary Relay Box 2 Relay ID - Before 2/18/02 > Page 9951 Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions License Plate Lamp: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. NOTE: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9956 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number or the component name in one of the the A-Z Component Lists, the Component Location description for that component can easily be found. See: Locations/Component Locations/A-Z Component List Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9957 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9958 the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9959 that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9960 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9961 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9962 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9963 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9964 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9965 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9966 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9967 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9968 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9969 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9970 Systems Overview Wire Color Code Identification Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9971 OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9972 License Plate Lamp: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9973 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9974 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9975 License Plate Lamp: Connector Views Connector View C452 Connector View C454 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9976 Connector View C462 Connector View C464 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9977 License Plate Lamp: Electrical Diagrams Diagram 92-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9978 Diagram 92-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9979 Diagram 92-5 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9980 Diagram 92-6 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9981 Diagram 92-7 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9982 Diagram 92-8 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9983 Diagram 92-9 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9984 Diagram 92-12 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9985 Diagram 92-13 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Page 9986 License Plate Lamp: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Parking Lamp; Testing and Inspection. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions Marker Lamp: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. NOTE: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9991 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number or the component name in one of the the A-Z Component Lists, the Component Location description for that component can easily be found. See: Locations/Component Locations/A-Z Component List Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9992 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9993 the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9994 that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9995 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9996 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9997 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9998 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9999 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10000 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10001 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10002 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10003 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10004 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10005 Systems Overview Wire Color Code Identification Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10006 OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10007 Marker Lamp: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10008 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10009 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10010 Marker Lamp: Electrical Diagrams Diagram 92-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10011 Diagram 92-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10012 Diagram 92-5 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10013 Diagram 92-6 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10014 Diagram 92-7 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10015 Diagram 92-8 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10016 Diagram 92-9 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10017 Diagram 92-12 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10018 Diagram 92-13 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations Parking Lamp Relay: Locations Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Page 10023 Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Page 10024 View 151-8 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Page 10025 Parking Lamp Relay: Diagrams Connector View C1095 Connector View C2059 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Page 10026 Parking Lamp Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Page 10027 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations Battery Discharge Protection Relay: Locations Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 10032 Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 10033 Connector View C2048 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 10034 Battery Discharge Protection Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 10035 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations Courtesy Lamp Relay: Locations Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations > Page 10039 Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations > Page 10040 Connector View C2022 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations > Page 10041 Courtesy Lamp Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations > Page 10042 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations View 151-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 10046 Connector View C1030 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 10047 Daytime Running Lamp Control Unit: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the Daytime Running Lamps (DRL) control module. 1 Disconnect the electrical connector. 2 Remove the bolts. 3 Remove the module. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Fog Lamp Relay Fog/Driving Lamp Relay: Locations Fog Lamp Relay Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Fog Lamp Relay > Page 10052 Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Fog Lamp Relay > Page 10053 Fog/Driving Lamp Relay: Locations Fog Lamp Isolation Relay Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Fog Lamp Relay > Page 10054 Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Fog Lamp Relay Connector View C1007 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Fog Lamp Relay > Page 10057 Connector View C1038 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Page 10058 Fog/Driving Lamp Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Page 10059 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Autolamp Headlamp Relay View 151-8 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Autolamp Headlamp Relay > Page 10064 Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Autolamp Headlamp Relay Connector View C2233 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Diagrams > Autolamp Headlamp Relay > Page 10067 Connector View C2234 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Testing and Inspection > Micro ISO Relay Headlamp Relay: Testing and Inspection Micro ISO Relay Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Testing and Inspection > Micro ISO Relay > Page 10070 Relay - Micro ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Testing and Inspection > Micro ISO Relay > Page 10071 Headlamp Relay: Testing and Inspection Mini ISO Relay Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Testing and Inspection > Micro ISO Relay > Page 10072 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 10076 Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 10077 Connector View C1006 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 10078 Horn Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 10079 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Auxiliary Relay Box 2 Relay ID - Before 2/18/02 Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Auxiliary Relay Box 2 Relay ID - Before 2/18/02 > Page 10084 Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Parking Lamp Relay: Locations Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 10088 Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 10089 View 151-8 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 10090 Parking Lamp Relay: Diagrams Connector View C1095 Connector View C2059 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 10091 Parking Lamp Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 10092 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations Trailer Lighting Relay: Locations Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 10096 Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 10097 Connector View C2049 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 10098 Trailer Lighting Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 10099 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Locations Turn Signal Relay: Locations Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Locations > Page 10103 Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Locations > Page 10104 Connector View C2047 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Locations > Page 10105 Turn Signal Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Locations > Page 10106 Relay - Micro ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations View 151-16 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 10111 Connector View C995 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations View 151-5 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Digital Transmission Range Sensor Connector View C167 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Digital Transmission Range Sensor > Page 10117 Connector View C169 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Diagrams Connector View C278 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Description and Operation > Brake Pedal Position Switch Brake Pedal Position Switch: Description and Operation Brake Pedal Position Switch Brake Pedal Position Switch Typical Brake Pedal Position Switch The Brake Pedal Position (BPP) switch (Figure 21) is used by the PCM to disengage the transmission torque converter clutch and on some applications as an input to the idle speed control for idle quality and for vehicle speed control deactivation. On most applications the BPP switch is hard wired to the PCM and supplies battery positive voltage (B+) when the vehicle brake pedal is applied. On other applications the BPP switch signal is broadcast over the SCP link via another module to be received by the PCM. On applications where the BPP switch is hard wired to the PCM and stoplamp circuit, if all stoplamp bulbs are burned out (open), high voltage is present at the PCM due to a pull-up resistor in the PCM. This provides fail-safe operation in the event the circuit to the stoplamp bulbs has failed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Description and Operation > Brake Pedal Position Switch > Page 10123 Brake Pedal Position Switch: Description and Operation Brake Pressure Applied Brake Deactivator Switch Brake Pressure Applied Brake Deactivator Switch The Brake Pressure Applied (BPA) switch also sometimes called the brake deactivator switch for vehicle speed control deactivation. Is a normally closed switch, witch supplies battery positive voltage (B+) to the PCM when the brake pedal is NOT applied. When the brake pedal is depressed, the normally closed switch will open and power is removed from the PCM. On some applications the normally closed BPA switch along with the normally open brake pedal position (BPP) switch are used for a brake rationality test within the PCM. The PCM misfire monitor profile learn function can be disable if a brake switch failure occurs. If one or both brake pedal inputs to the PCM did not change states when they were expected to a diagnostic trouble code P1572 can be set by the PCM strategy. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Description and Operation > Page 10124 Brake Pedal Position Switch: Service and Repair REMOVAL 1. Disconnect the Brake Pedal Position (BPP) switch electrical connector. 2. Remove the BPP switch. 1 Remove the self-locking pin. 2 Remove the spacer. 3 Remove the BPP switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Left Connector View C458 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Left > Page 10129 Connector View C459 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Left > Page 10130 Door Switch: Diagrams Driver Side Front Connector View C526a Connector View C526b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Left > Page 10131 Door Switch: Diagrams Driver Side Rear Connector View C715a Connector View C715b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Left > Page 10132 Door Switch: Diagrams Connector View C458 Connector View C459 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Left > Page 10133 Connector View C526a Connector View C526b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Left > Page 10134 Connector View C715a Connector View C715b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Left > Page 10135 Connector View C602a Connector View C602b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Left > Page 10136 Connector View C820a Connector View C820b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch Door Switch: Service and Repair Door Ajar Switch REMOVAL 1. Remove the door interior trim panel. NOTE: Front door shown, rear door similar. 2. Position the watershield aside. 3. Disconnect the ground wire and remove the screw. 4. Remove the door ajar switch. - Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch > Page 10139 Door Switch: Service and Repair Door Ajar Switch - Liftgate REMOVAL 1. Remove the liftgate latch. 2. Remove the liftgate latch ajar switch. - Remove the screw. INSTALLATION 1. To install, reverse the removal process. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams Connector View C240 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Page 10143 Fog/Driving Lamp Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the instrument panel finish panel. 1 Remove the screws. 2 Remove the center instrument panel finish panel. ^ Disconnect the electrical connectors. 3. Remove the fog lamp switch. 1 Remove the screws. 2 Remove the mounting bezel. 3 Release the two tabs and remove the fog lamp switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams Hazard Warning Switch: Diagrams Connector View C202a Connector View C202b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 10147 Hazard Warning Switch: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 10148 Multifunction Switch, Turn Portion Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 10149 Multifunction Switch, Turn Portion Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams Headlamp Dimmer Switch: Diagrams Connector View C202a Connector View C202b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 10153 Headlamp Dimmer Switch: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 10154 Multifunction Switch, Lamp Portion Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 10155 Multifunction Switch, Lamp Portion Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams Connector View C205 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 10159 Main Light Switch: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 10160 Main Light Switch, Exterior Lamps, Illumination Lamps Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 10161 Main Light Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the instrument panel center finish panel. 1 Remove the screws. 2 Remove the instrument panel center finish panel. ^ Disconnect electrical connectors. 3. Remove the hood latch release handle. 1 Remove the screws. 2 Remove the hood latch release handle. 4. Remove the lower instrument panel steering column cover. 1 Remove the screws. 2 Remove the lower instrument panel steering column cover. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 10162 5. Remove the bolts and the lower instrument panel reinforcement. 6. If equipped, position the column gear shift lever out of the way. 7. Position the cluster finish panel aside. 1 Remove the screws. 2 Position the cluster finish panel aside. 8. Remove the cluster finish pane 1 Disconnect the electrical connectors and remove the headlamp switch knob. 2 Remove the cluster finish panel. 9. Remove the headlamp switch. 1 Remove the screws. 2 Remove the headlamp switch. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 10163 INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service and Repair Horn Switch: Service and Repair REMOVAL 1. Remove the driver side air bag. 2. Remove the switch. 1 Disconnect the horn wire (BK) from the switches. 2 Remove the screws and the switch. INSTALLATION 3. To install, reverse the removal procedure. ^ Prove out the air bag system; refer to Air Bag Systems. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications Turn Signal Switch: Specifications Multi-Function Switch Screws ................................................................................................................................................. 2.1 2.9 Nm (19 - 25 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 10170 Turn Signal Switch: Diagrams Connector View C202a Connector View C202b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 10171 Turn Signal Switch: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 10172 Multifunction Switch, Turn Portion Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 10173 Multifunction Switch, Turn Portion Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 10174 Turn Signal Switch: Service and Repair Multifunction Switch Removal and Installation 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the upper and lower steering column shrouds. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Specifications > Page 10175 5. Remove the multifunction switch. 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the multifunction switch. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions Tail Lamp: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. NOTE: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10180 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number or the component name in one of the the A-Z Component Lists, the Component Location description for that component can easily be found. See: Locations/Component Locations/A-Z Component List Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10181 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10182 the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10183 that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10184 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10185 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10186 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10187 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10188 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10189 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10190 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10191 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10192 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10193 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10194 Systems Overview Wire Color Code Identification Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10195 OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10196 Tail Lamp: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10197 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10198 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10199 Tail Lamp: Electrical Diagrams Diagram 92-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10200 Diagram 92-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10201 Diagram 92-5 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10202 Diagram 92-6 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10203 Diagram 92-7 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10204 Diagram 92-8 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10205 Diagram 92-9 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10206 Diagram 92-12 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10207 Diagram 92-13 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Page 10208 Tail Lamp: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Parking Lamp; Testing and Inspection. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Page 10209 Tail Lamp: Service and Repair REMOVAL 1. Lower the tailgate. 2. Remove the plugs. 3. Remove the rear lamp assembly. 1 Remove the bolts. 2 Pull the lamp assembly rearward. ^ Disconnect the electrical connectors. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions Trailer Lamps: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Types of Diagrams Shown Block Diagrams can be found at the beginning of some sets of diagrams. These block diagrams provide an overview of the systems that are detailed on the detailed diagrams that follow them. Block diagrams are not suitable for diagnostic operations. Detailed Diagrams (usually provided in sets of more than one diagram) provide detailed system information suitable for diagnostic operations. Related Diagrams that are not an intergal part of the detailed diagrams, but may have a relationship to them, are also included. All components connected to the control module are shown in order to provide easy understanding of the system component interactions. Unless otherwise identified, diagrams shown in a set will be of the Detailed Diagrams type. NOTE: All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagram to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10214 Current Flow (1) Each set of diagrams normally starts with the component that powers the circuit such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. Switch Positions (2) Within the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) An arrow indicates that the splice is not shown completely. If the splice is not shown completely in the diagram but is complete within the set of diagrams, the number of the diagram where the splice is completed is indicated next to the arrow. Boxes (4) A thin dashed box on a diagram indicates a pan of the circuit which is only present for a particular vehicle model, country, or option. These qualifiers are shown next to the box on the diagram. Component Names and Notes (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. Component Identification Numbers (6) Each component on each diagram has a component identification number located to the upper right hand side of the component. By finding this number or the component name in one of the the A-Z Component Lists, the Component Location description for that component can easily be found. See: Locations/Component Locations/A-Z Component List Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10215 Fuse And Relay Information Fuse and Relay Information Fuse Box/Locations and Relay Box/Locations contain views of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power Distribution "Power Distribution" shows the current feed circuit. The Current path is shown from the battery to the ignition switch and to all fuses. Fuse Circuits Fuse Circuits The first diagram in "Fuse Circuits" shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Any subsequent diagrams will show circuits feeding the fuse, all the way back to the battery. Ground Distribution Ground Distribution "Ground Distribution" contains the diagrams that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10216 the ground point and the components are shown. These ground connection details are shown here in order to keep the individual sets of diagrams as uncluttered as possible. Splices with a large number of wires may be split in order to improve the graphic representation. A thin line is used to indicate the unity of the splice. The splice is then marked with the additional text "partial". Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Vacuum Motor Operation Vacuum motors operate like electrical solenoids, mechanically pushing or pulling a shaft between two fixed positions. When vacuum is not applied, the shaft is pushed all the way out by a spring. Some vacuum motors can position the actuating arm at any position between fully extended and fully retracted. The Servo is operated by a control valve that applies varying amounts of vacuum to the motor. The higher the vacuum level, the greater the retraction of the motor arm. Servo Motors work nearly the same way as two-position motors, except for the way the vacuum is applied. Servo Motors are generally larger and provide a calibrated control. A double diaphragm motor has three positions (it is actually two motors in one housing). When the top port gets vacuum, the shaft pulls halfway in. When both ports get vacuum, the shaft pulls all the way in. WARNINGS ^ Always wear safety glasses for eye protection. ^ Use safety stands whenever a procedure requires being under a vehicle. ^ Be sure that the Ignition Switch is always in the OFF position, unless otherwise required by the procedure. ^ Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. ^ Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. ^ Keep away from moving parts, especially the fan and belts, when the engine is running. ^ To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tall pipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery. An explosion could occur. ^ Do not smoke when working on a vehicle. ^ To avoid injury always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. circuit Numbering Circuit Numbering and Wire Identification Circuit Numbering: Ford has introduced a world-wide uniform system for circuit numbering and wire identification. The system is called Function, System-Connection, or FSC for short. FSC was developed mainly to assist in vehicle development and production processes, but is also helpful in troubleshooting electrical circuits. Function: The first two digits identify the function of the wire. In this case, the function code includes the letter "S" to indicate it is an additionally switched function. The function part of the circuit number is the most helpful to the technician in troubleshooting a circuit. System-Connection (including branch): Systems are related to subsets of the vehicle circuitry. Immediately following the system letter code is the connection number specific to Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10217 that system. A branch identification is used to differentiate wires in one connection with the same function. Wire Identification (wire colors): The wire identification consists of a basic color and an identification color, and is determined directly from the wire's circuit number. In the schematics the wire colors are indicated next to the wires. The basic and identification colors are abbreviated using the international norm IEC 757. Each function code has a specific basic color associated with it. A colored stripe is used to differentiate several wires with the same function within one component connector. Wire Identification Example Using the circuit number and wire identification used in the Wire Identification Example, we know the following information about the wire: Function: 31 = Ground S = Additionally switched circuit System: AC = Headlamp leveling Connection: 3 = Switch connection A = Branch Size: 1.5 = 1.5 sq.mm Color: BK = Basic color black (determined by function 31) RD = Identification color red (red stripe). Circuit Identification Charts Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10218 Circuit Identification Chart System Codes Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10219 Sample Diagrams Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10220 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10221 Sample Diagram Circuit Identification Charts and System Codes CIRCUIT IDENTIFICATION CHARTS Circuit Identification Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10222 Circuit Identification Chart SYSTEM CODES CHART Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10223 SAMPLE DIAGRAMS Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10224 Sample Diagram Sample Diagram Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10225 Sample Diagram Electrical Symbols ELECTRICAL SYMBOLS Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10226 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10227 Symbols Symbols Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10228 Systems Overview Wire Color Code Identification Wire colors BK : Black BN : Brown BU : Blue GN : Green GY : Gray LG : Lightgreen NA : Natural Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10229 OG : Orange RD : Red SR : Silver VT : Violet WH : White YE : Yellow Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10230 Trailer Lamps: Diagnostic Aids These illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10231 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10232 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10233 Trailer Lamps: Electrical Diagrams Diagram 95-1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10234 Diagram 95-2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10235 Diagram 95-3 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10236 Diagram 95-4 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10237 Diagram 95-5 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Trailer Lamps: Initial Inspection and Diagnostic Overview 1. Verify the customer concern. 2. Verify the exterior lighting system of the vehicle is operating correctly. If not, refer to the appropriate pinpoint test. 3. Visually inspect for obvious signs of mechanical or electrical damage. VISUAL INSPECTION CHART Electrical ^ Central junction box (CJB) fuse(s): 3 (7.5A) - 7 (7.5A) - 19 (15A) (late production) - 36 (15A) (early production) ^ Circuitry ^ Trailer tow relay ^ Bulb(s) 4. If the fault is not visually evident, determine the symptom and go to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10240 Symptom Chart Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10241 Trailer Lamps: Pinpoint Tests Connector Circuit Reference Refer to Vehicle/Diagrams for schematic and connector information. Y1 Z1 - Z2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10242 Z2 AA1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10243 AB1 AC1 - AC2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10244 AC2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10245 73III Automotive Meter Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Page 10246 73III Automotive Meter Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations Trailer Lighting Relay: Locations Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 10250 Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 10251 Connector View C2049 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 10252 Trailer Lighting Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 10253 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Park/Turn Lamp, Left Front Connector View C1023 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Park/Turn Lamp, Left Front > Page 10259 Connector View C1043 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Park/Turn Lamp, Left Front > Page 10260 Connector View C4032 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Park/Turn Lamp, Left Front > Page 10261 Connector View C4035 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Locations Turn Signal Relay: Locations Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Locations > Page 10265 Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Locations > Page 10266 Connector View C2047 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Locations > Page 10267 Turn Signal Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Locations > Page 10268 Relay - Micro ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Specifications Turn Signal Switch: Specifications Multi-Function Switch Screws ................................................................................................................................................. 2.1 2.9 Nm (19 - 25 ft. lbs.) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Specifications > Page 10272 Turn Signal Switch: Diagrams Connector View C202a Connector View C202b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Specifications > Page 10273 Turn Signal Switch: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Specifications > Page 10274 Multifunction Switch, Turn Portion Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Specifications > Page 10275 Multifunction Switch, Turn Portion Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Specifications > Page 10276 Turn Signal Switch: Service and Repair Multifunction Switch Removal and Installation 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the upper and lower steering column shrouds. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Specifications > Page 10277 5. Remove the multifunction switch. 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the multifunction switch. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations View 151-9 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 10283 Connector View C2021 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 10284 Heated Glass Element Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 10285 Relay - Micro ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Diagrams Connector View C241 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations View 151-9 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 10293 Connector View C2021 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 10294 Heated Glass Element Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 10295 Relay - Micro ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Application and ID Power Window Control Module: Application and ID For further information please see Accessories and Optional Equipment, General Module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Window Safety Relay Power Window Relay: Locations Window Safety Relay Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Window Safety Relay > Page 10303 Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Window Safety Relay > Page 10304 Power Window Relay: Locations One-Touch Window Relay Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Window Safety Relay > Page 10305 Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Window Safety Relay Power Window Relay: Diagrams Window Safety Relay Connector View C1096 Connector View C2058 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Window Safety Relay > Page 10308 Connector View C2051 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > Micro ISO Relay Power Window Relay: Testing and Inspection Micro ISO Relay Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > Micro ISO Relay > Page 10311 Relay - Micro ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > Micro ISO Relay > Page 10312 Power Window Relay: Testing and Inspection Mini ISO Relay Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Testing and Inspection > Micro ISO Relay > Page 10313 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Diagrams Connector View C241 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Rear Window Adjust Switch Connector View C2060 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Rear Window Adjust Switch > Page 10322 Power Window Switch: Diagrams Master Window Adjust Switch Connector View C504a Connector View C504b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Rear Window Adjust Switch > Page 10323 Connector View C701 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Rear Window Adjust Switch > Page 10324 Connector View C604 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Rear Window Adjust Switch > Page 10325 Connector View C801 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch Power Window Switch: Testing and Inspection Master Window Adjust Switch Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 10328 Master Window Adjust Switch Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 10329 Master Window Adjust Switch Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 10330 Power Window Switch: Testing and Inspection Power window Switch Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 10331 Power Window Switch, Passenger Door Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 10332 Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 10333 Power Window Switch, LH Side Rear Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 10334 Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 10335 Power Window Switch, RH Side Rear Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Page 10336 Power Window Switch: Service and Repair REMOVAL NOTE: Driver window control switch shown, all others are similar. Front door 1. Disconnect the battery ground cable. All doors 2. Remove the window control switch panel. ^ Disconnect the electrical connectors. 3. Remove the window control switch. ^ Release the locking clips. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Application and ID Power Window Control Module: Application and ID For further information please see Accessories and Optional Equipment, General Module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Diagrams > Left Front Connector View C524 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Diagrams > Left Front > Page 10346 Connector View C608 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Diagrams > Page 10347 Front Door Window Motor: Service Precautions CAUTION: Make sure that no obstructions are present in the power rear window system when carrying out this procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Diagrams > Page 10348 Front Door Window Motor: Service and Repair REMOVAL 1. Remove the front door trim panel. 2. Remove the front door speaker. 1 Remove the screws. 2 Disconnect the electrical connector. 3 Remove the speaker. 3. Remove the water shield. 4. Disconnect the front door window regulator motor electrical connector. 5. Drill a 13 mm (0.52 in) hole using the locator in the door sheet metal as a guide. 6. Remove the bolts and the front door window regulator motor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Diagrams > Page 10349 INSTALLATION 1. To install, reverse the removal procedure. ^ Cycle the door glass to make sure of engagement of the drive mechanism. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Technical Service Bulletins > Customer Interest for Rear Door Window Motor: > 07-20-5 > Oct > 07 > Body - Rear Door Window Stuck In Up Position/Inoperative Rear Door Window Motor: Customer Interest Body - Rear Door Window Stuck In Up Position/Inoperative TSB 07-20-5 10/15/07 REAR POWER WINDOW MOTOR INOPERATIVE/STUCK IN THE UP POSITION FORD: 2002-2005 Explorer Sport Trac 2002-2006 Explorer LINCOLN: 2003-2005 Aviator MERCURY: 2002-2006 Mountaineer This article supersedes TSB 07-16-14 to update the Part List. ISSUE Some 2002-2006 Explorer, Mountaineer and 2002-2005 Explorer Sport Trac, and 2003-2005 Aviator vehicles built before 1/23/2006 may experience a rear power window that sticks in the up position. This condition can be intermittent and may be due to the power motor which temporarily locks up. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Use the current Workshop Manual (WSM), Section 501-11 procedure to remove the door panel and inspect the window regulator for damaged parts. 2. If any damage part or parts are found replace the regulator assembly. 3. If no damaged parts are found on the regulator assembly, replace the window regulator motor using WSM, Section 501-11. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072005A 2002-2005 Explorer Sport 0.9 Hr. Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B 27406B8, 27406B9) 072005B 2002-2005 Explorer Sport 1.6 Hrs. Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Technical Service Bulletins > Customer Interest for Rear Door Window Motor: > 07-20-5 > Oct > 07 > Body - Rear Door Window Stuck In Up Position/Inoperative > Page 10358 To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9) 072005C 2002-2006 0.4 Hr. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B, 27406B8, 27406B9) 072005D 2002-2006 0.7 Hr. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9) 072005E 2002-2006 0.6 Hr. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B, 27406B8, 27406B9) 07200SF 2002-2006 1.1 Hrs. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9) DEALER CODING CONDITION BASIC PART NO. CODE 7823394 07 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Motor: > 07-20-5 > Oct > 07 > Body - Rear Door Window Stuck In Up Position/Inoperative Rear Door Window Motor: All Technical Service Bulletins Body - Rear Door Window Stuck In Up Position/Inoperative TSB 07-20-5 10/15/07 REAR POWER WINDOW MOTOR INOPERATIVE/STUCK IN THE UP POSITION FORD: 2002-2005 Explorer Sport Trac 2002-2006 Explorer LINCOLN: 2003-2005 Aviator MERCURY: 2002-2006 Mountaineer This article supersedes TSB 07-16-14 to update the Part List. ISSUE Some 2002-2006 Explorer, Mountaineer and 2002-2005 Explorer Sport Trac, and 2003-2005 Aviator vehicles built before 1/23/2006 may experience a rear power window that sticks in the up position. This condition can be intermittent and may be due to the power motor which temporarily locks up. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Use the current Workshop Manual (WSM), Section 501-11 procedure to remove the door panel and inspect the window regulator for damaged parts. 2. If any damage part or parts are found replace the regulator assembly. 3. If no damaged parts are found on the regulator assembly, replace the window regulator motor using WSM, Section 501-11. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072005A 2002-2005 Explorer Sport 0.9 Hr. Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B 27406B8, 27406B9) 072005B 2002-2005 Explorer Sport 1.6 Hrs. Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Motor: > 07-20-5 > Oct > 07 > Body - Rear Door Window Stuck In Up Position/Inoperative > Page 10364 To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9) 072005C 2002-2006 0.4 Hr. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B, 27406B8, 27406B9) 072005D 2002-2006 0.7 Hr. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9) 072005E 2002-2006 0.6 Hr. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B, 27406B8, 27406B9) 07200SF 2002-2006 1.1 Hrs. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9) DEALER CODING CONDITION BASIC PART NO. CODE 7823394 07 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Diagrams > Left Connector View C703 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Diagrams > Left > Page 10367 Connector View C351 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Diagrams > Left > Page 10368 Connector View C803 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Diagrams > Page 10369 Rear Door Window Motor: Service Precautions CAUTION: Make sure that no obstructions are present in the power rear window system when carrying out this procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Service and Repair > Rear Door Window Regulator Motor Rear Door Window Motor: Service and Repair Rear Door Window Regulator Motor REMOVAL 1. Remove the rear door window regulator. 2. Remove the rear door window regulator motor. 1 Remove the bolts. 2 Remove the rear door window regulator motor. INSTALLATION 1. To install, reverse the removal procedure. ^ Cycle the door glass to make sure of engagement of the drive mechanism. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Service and Repair > Rear Door Window Regulator Motor > Page 10372 Rear Door Window Motor: Service and Repair Rear Window Glass Motor REMOVAL NOTE: ^ The power rear window motor can be removed and a new one installed without removing the seat or trim panel. ^ When the power rear window motor is removed and installed, the motor must be initialized. 1. Fold down the passenger rear seat back. 2. Open the luggage compartment trim panel access door. 3. Remove the spare tire jack and handle assembly. 4. Position the carpet aside and position the water shield back from the rear window glass motor to access bolts. NOTE: The rear window glass water shield uses a reusable butyl rubber adhesive. A new water shield does not have to be installed unless it is damaged or if the butyl rubber adhesive does not adhere to a section of the sheet metal. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Service and Repair > Rear Door Window Regulator Motor > Page 10373 5. Remove the rear window motor. 1 Disconnect the electrical connector. 2 Remove the bolts. 3 Remove the rear window glass motor. CAUTION: Use care not to damage the drum housing when removing the rear window glass motor. NOTE: Apply pressure to the drum while removing the rear window motor to avoid extraction of the drum with the motor. INSTALLATION 1. To install, reverse the removal procedure. NOTE: The rear window motor must be initialized after a repair is carried out. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Service and Repair > Rear Door Window Regulator Motor > Page 10374 Rear Door Window Motor: Service and Repair Rear Window Motor Initialization CAUTION: Make sure that no obstructions are present in the power rear window system when carrying out this procedure. NOTE: ^ This procedure must be carried out when repairs are performed on any part of the power rear window system including when: the power rear window motor is removed from the window regulator drum housing, a new power rear motor is installed, a new power rear window regulator is installed, a new power rear window module is installed, and any operation in which grease or lubricants are applied to the power rear window system. ^ All power rear window components (window glass module, window regulator, window motor, and glass runs) must be installed and torqued to specification before carrying out this procedure. ^ Steps 1-6 must be completed within 30 seconds. The entire procedure must be completed within five minutes. ^ Once the ignition key is turned to the ON position in Step 6, it must remain on until the entire procedure is completed. ^ Steps 7 and 9 require that the power rear window control switch be held in the closed position until the power rear window motor stalls the window in the upper header seal. Step 8 requires that the window control switch be momentarily turned to the open position. 1. Start with the ignition in the OFF position. 2. Turn the ignition to the ON position. 3. Press the power rear window control switch vent button six times. 4. Turn the ignition to the OFF position. 5. Press the power rear window control switch vent button six times. 6. Turn the ignition to the ON position. The power rear window will move up-down-up-down approximately 20 mm (0.8 in). This movement indicates that the power rear window motor has entered initialized mode. 7. Rotate and hold the power rear window control switch to the closed position until the window stalls in the upper header seal. 8. Momentarily rotate the power rear window control switch to the open position and release. The power rear window will carry out a one-touch down operation until the window stalls at the bottom of the travel stop designed into the window regulator. 9. Rotate and hold the power rear window control switch to the closed position until the window stalls into the upper header seal. Once this operation is complete, the window will move up-down-up-down approximately 20 mm (0.8 in). This movement indicates that the power rear window motor has been successfully initialized. 10. Verify correct operation of the power rear window by moving the window to the fully open, vent, then fully closed positions. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations > Window Safety Relay Power Window Relay: Locations Window Safety Relay Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations > Window Safety Relay > Page 10379 Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations > Window Safety Relay > Page 10380 Power Window Relay: Locations One-Touch Window Relay Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations > Window Safety Relay > Page 10381 Auxiliary Relay Box 2 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Diagrams > Window Safety Relay Power Window Relay: Diagrams Window Safety Relay Connector View C1096 Connector View C2058 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Diagrams > Window Safety Relay > Page 10384 Connector View C2051 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Testing and Inspection > Micro ISO Relay Power Window Relay: Testing and Inspection Micro ISO Relay Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Testing and Inspection > Micro ISO Relay > Page 10387 Relay - Micro ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Testing and Inspection > Micro ISO Relay > Page 10388 Power Window Relay: Testing and Inspection Mini ISO Relay Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Testing and Inspection > Micro ISO Relay > Page 10389 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Rear Window Adjust Switch Connector View C2060 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Rear Window Adjust Switch > Page 10394 Power Window Switch: Diagrams Master Window Adjust Switch Connector View C504a Connector View C504b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Rear Window Adjust Switch > Page 10395 Connector View C701 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Rear Window Adjust Switch > Page 10396 Connector View C604 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Rear Window Adjust Switch > Page 10397 Connector View C801 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch Power Window Switch: Testing and Inspection Master Window Adjust Switch Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 10400 Master Window Adjust Switch Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 10401 Master Window Adjust Switch Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 10402 Power Window Switch: Testing and Inspection Power window Switch Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 10403 Power Window Switch, Passenger Door Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 10404 Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 10405 Power Window Switch, LH Side Rear Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 10406 Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 10407 Power Window Switch, RH Side Rear Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Page 10408 Power Window Switch: Service and Repair REMOVAL NOTE: Driver window control switch shown, all others are similar. Front door 1. Disconnect the battery ground cable. All doors 2. Remove the window control switch panel. ^ Disconnect the electrical connectors. 3. Remove the window control switch. ^ Release the locking clips. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Window Frame > Component Information > Service Precautions Window Frame: Service Precautions CAUTION: Use care not to damage the pin-type retainers retaining the upper corner of the door glass top run. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Window Frame > Component Information > Service and Repair > Front Door Glass Top Run Window Frame: Service and Repair Front Door Glass Top Run REMOVAL 1. Remove the front door trim panel. 2. Remove the interior glass weather strip. 3. Position aside the water shield. 4. Remove the exterior rear view mirror. 5. Release the two pin-type retainers. CAUTION: Use care not to damage the pin-type retainers retaining the upper corner of the door glass top run. 6. Remove the front door glass top run bolts. 7. Remove the front door glass top run. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Window Frame > Component Information > Service and Repair > Front Door Glass Top Run > Page 10414 Window Frame: Service and Repair Rear Door Glass Top Run REMOVAL 1. Remove the rear door window glass. 2. Remove the rear door glass top run bolt. 3. Remove the door glass top run. CAUTION: Use care not to damage the pin-type retainers retaining the upper forward corner of the door glass top run. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Fixed Back Window Glass: Service and Repair Fixed REMOVAL 1. Remove the C-pillar trim panel. 2. Remove the 15 rear window glass nuts and remove the rear window glass. 3. Remove the excess foam butyl from the window opening. INSTALLATION 1. To install, reverse the removal procedure. ^ Apply 6 mm (0.23 in) Foam Butyl or equivalent meeting Ford specification WSB-M2G234-C to the rear window glass. ^ Start at the bottom middle and work around the window opening. NOTE: When applying foam butyl, leave a slight overlap at the bottom to allow for drainage. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Fixed > Page 10420 Back Window Glass: Service and Repair Power REMOVAL 1. Fold down the rear seat backs. 2. Fold the loadspace trim panels up and remove the luggage compartment lower screws and loadspace trim panel. 3. Remove the pin-type retainers from the luggage compartment trim panel. 4. Open the luggage compartment trim panel access doors and remove the four pin-type retainers and the luggage compartment trim panel. 5. Remove the spare tire and jack assembly. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Fixed > Page 10421 6. Remove the roof trim panel. 7. Remove the C-pillar safety belt guide bolts and position the safety belt guides aside. 8. Remove the pin-type retainer and position the C-pillar trim panels aside. 9. Remove the carpet pin-type retainers and pull the carpet back. NOTE: Do not remove the power rear window motor water shield. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Fixed > Page 10422 10. Position the rear window glass regulator access panel aside. 1 Remove the screws. 2 Remove the nut. 3 Position the rear window glass regulator access panel aside. 11. Position the rear window glass to the 3/4 down position. 12. Remove the rear window weatherstrip moulding. 13. Remove the rear window glass bolts. 14. Secure the rear window glass in the full up position. NOTE: When securing the rear window glass note that the rear window glass and module will be removed with the rear window glass in the secured position. 15. Remove the 12 rear window glass module nuts. 16. Push the rear window glass module out at the top. 17. Lift the rear window glass module from the rear of the cab to disengage the locating clip. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Fixed > Page 10423 NOTE: In order for the rear widow glass to function correctly the locating clip must engage the pinch weld at the rear of the cab during installation. 18. Remove the excess foam butyl from the window opening. 19. If necessary, remove the center rear window glass from the module. INSTALLATION 1. To install, reverse the removal procedure. ^ Apply 6 mm (0.23 in) foam butyl or equivalent meeting Ford specification WSB-M2G234-C to the rear window glass module. ^ Start at the bottom and work around the module. 2. Reinitialize the rear window glass motor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Fixed > Page 10424 Back Window Glass: Service and Repair Rear Window Positioning CAUTION: ^ Make sure that no obstructions are present in the power rear window system when carrying out this procedure. ^ If the glass/regulator system is binding, the system must be diagnosed and a new component must be installed. Do not apply hand pressure to glass that does not move freely. NOTE: ^ Because the power rear window removal/installation position is approximately three-quarters down and the power rear window motor can only move the window to three positions, a special procedure is necessary to position the window to the removal/installation position. ^ If the power rear window motor does not respond to this procedure, refer to the diagnosis and testing for repair. If the window must be removed and the window motor does not respond to this procedure, remove the window motor. The window then can be moved by carefully applying hand pressure in the downward direction. ^ By only partially performing the power rear window motor initialization procedure, the window motor will enter error mode. In error mode, no window motor movement is possible and the window motor will have to be re-initialized. Refer to Rear Window Motor Initialized. ^ Steps 1-6 must be completed within 30 seconds. 1. Start with the ignition in the OFF position. 2. Turn the ignition to the ON position. 3. Press the power rear window control switch vent button six times. 4. Turn the ignition to the OFF position. 5. Press the power rear window control switch vent button six times. 6. Turn the ignition to the ON position. The power rear window will move up-down-up-down approximately 20 mm (0.8 in). This movement indicates that the window motor has entered initialized mode. 7. Rotate and hold the power rear window control switch to the closed position until the window stalls in the upper header seal. 8. Momentarily rotate the power rear window control switch to the open position and release. The window will carry out a one-touch down operation until the window stalls at the bottom of the travel stop designed into the window regulator. 9. Rotate and hold the power rear window control switch to the closed position momentarily until the window regulator glass attach nuts are lined up with the sheet metal access holes. The window will be approximately in the three-quarter down position when installed to the window regulator. 10. Repeat this procedure if the window regulator glass attach nuts are raised too far above the sheet metal access holes. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Service and Repair Front Door Window Glass: Service and Repair Heavy Duty Riverter SPECIAL TOOL(S) REMOVAL 1. Remove the front door trim panel. 2. Remove the front door belt line moulding. 1 Remove the nut. 2 Remove the moulding. CAUTION: Do not strike or force the front door belt line moulding during installation. The front door belt line moulding is made of aluminum and will be damaged. NOTE: During installation, make sure that the front door belt line moulding fits flush with the edge of the sheet metal and the door panel shelf. 3. Remove the interior glass weatherstrip. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Service and Repair > Page 10428 4. Remove the front door window glass rivets. NOTE: Lower the window glass to access the rivets. 5. Remove the front door window glass through the outboard side of the front door. INSTALLATION 1. To install, reverse the removal procedure. ^ Use the special tool to install the rivets. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair Liftgate Window Glass: Service and Repair REMOVAL 1. Open the liftgate glass. 2. Remove the two heated rear window electrical connector covers. 3. Disconnect the two heated rear window electrical connectors. 4. Remove the two liftgate lifting cylinder pins. NOTE: An assistant may be needed to carry out this step. 5. Remove the liftgate window glass. 1 Position the liftgate trim panel aside. 2 Remove the access the covers and the liftgate window hinge nuts. NOTE: An assistant may be needed to carry out this step. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair > Page 10432 6. Remove the liftgate window glass. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Fixed Quarter Window Glass: Service and Repair Fixed REMOVAL 1. Remove the quarter trim panel. 2. Remove the rear quarter window glass. 1 Remove the nuts. 2 Push the rear quarter window glass outward to release the butyl seal. 3. Remove the excess foam butyl from the window opening. INSTALLATION 1. Apply 6 mm (0.23 in) Foam Butyl or equivalent meeting Ford specification WSB-M2G234-C to the rear quarter window glass frame. ^ Start at the bottom middle and work around the frame. NOTE: When applying foam butyl, leave a slight overlap at the bottom to allow for drainage. 2. Install the rear quarter window glass. 1 Position the rear quarter window glass. 2 Tighten the nuts. 3. Install the quarter trim panel. NOTE: Loosely install the nuts before tightening. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Fixed > Page 10437 Quarter Window Glass: Service and Repair Movable Quarter REMOVAL 1. Remove the quarter trim panel. 2. Remove the quarter window glass. 1 Remove the nuts. 2 Remove the quarter window glass. INSTALLATION 1. To install, reverse the removal procedure. ^ If the seal requires adjustment, disconnect the quarter window latch from the quarter trim panel. Rotate the quarter window latch clockwise to increase seal pressure or counterclockwise to reduce seal pressure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System Information > Service and Repair Rear Door Window Glass: Service and Repair Heavy Duty Riverter SPECIAL TOOL(S) REMOVAL 1. Remove the rear door trim panel. 2. Remove the interior glass weatherstrip. 3. Remove the rear door belt line moulding nut. 4. Remove the rear door belt line moulding. CAUTION: Do not strike or force the front door belt line moulding during the installation. The front door belt line moulding is made of aluminum and will be damaged. NOTE: During installation, make sure that the front door belt line moulding fits flush with the edge of the sheet metal and the door panel shelf. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System Information > Service and Repair > Page 10441 5. Position aside the water shield. 6. Connect the power window switch. 7. Remove the rear door window glass rivets. ^ Lower the glass approximately two-inches to access the rivets through the holes. 8. Carefully lower the window regulator while holding the glass. ^ Lower the glass. 9. Separate the front of the window run/weatherstrip from the door. 10. Remove the rear door window glass through the outboard side of the rear door. INSTALLATION 1. To install, reverse the removal procedure. ^ Use the special tool to install the rivets. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair Front Door Window Regulator: Service and Repair Heavy Duty Riverter SPECIAL TOOL(S) REMOVAL 1. Raise the front door window glass to the full up position. 2. Remove the interior door handle. 3. Support the front door window glass. 4. Disconnect the front door window regulator motor electrical connector. 5. Remove the equalizer bracket nuts. 6. Remove the front door window regulator. 1 Remove the rivets. 2 Remove the nut. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Page 10446 7. Remove the front door window regulator motor. 1 Remove the bolts. 2 Remove the front door window regulator motor. INSTALLATION 1. To install, reverse the removal procedure. ^ Use the special tool to install the rivets. ^ Cycle the door glass to make sure of engagement of the drive mechanism. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Page 10447 Heavy Duty Riveter Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Technical Service Bulletins > Customer Interest for Rear Door Window Regulator: > 07-20-5 > Oct > 07 > Body - Rear Door Window Stuck In Up Position/Inoperative Rear Door Window Regulator: Customer Interest Body - Rear Door Window Stuck In Up Position/Inoperative TSB 07-20-5 10/15/07 REAR POWER WINDOW MOTOR INOPERATIVE/STUCK IN THE UP POSITION FORD: 2002-2005 Explorer Sport Trac 2002-2006 Explorer LINCOLN: 2003-2005 Aviator MERCURY: 2002-2006 Mountaineer This article supersedes TSB 07-16-14 to update the Part List. ISSUE Some 2002-2006 Explorer, Mountaineer and 2002-2005 Explorer Sport Trac, and 2003-2005 Aviator vehicles built before 1/23/2006 may experience a rear power window that sticks in the up position. This condition can be intermittent and may be due to the power motor which temporarily locks up. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Use the current Workshop Manual (WSM), Section 501-11 procedure to remove the door panel and inspect the window regulator for damaged parts. 2. If any damage part or parts are found replace the regulator assembly. 3. If no damaged parts are found on the regulator assembly, replace the window regulator motor using WSM, Section 501-11. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072005A 2002-2005 Explorer Sport 0.9 Hr. Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B 27406B8, 27406B9) 072005B 2002-2005 Explorer Sport 1.6 Hrs. Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Technical Service Bulletins > Customer Interest for Rear Door Window Regulator: > 07-20-5 > Oct > 07 > Body - Rear Door Window Stuck In Up Position/Inoperative > Page 10456 To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9) 072005C 2002-2006 0.4 Hr. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B, 27406B8, 27406B9) 072005D 2002-2006 0.7 Hr. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9) 072005E 2002-2006 0.6 Hr. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B, 27406B8, 27406B9) 07200SF 2002-2006 1.1 Hrs. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9) DEALER CODING CONDITION BASIC PART NO. CODE 7823394 07 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > 07-20-5 > Oct > 07 > Body - Rear Door Window Stuck In Up Position/Inoperative Rear Door Window Regulator: All Technical Service Bulletins Body - Rear Door Window Stuck In Up Position/Inoperative TSB 07-20-5 10/15/07 REAR POWER WINDOW MOTOR INOPERATIVE/STUCK IN THE UP POSITION FORD: 2002-2005 Explorer Sport Trac 2002-2006 Explorer LINCOLN: 2003-2005 Aviator MERCURY: 2002-2006 Mountaineer This article supersedes TSB 07-16-14 to update the Part List. ISSUE Some 2002-2006 Explorer, Mountaineer and 2002-2005 Explorer Sport Trac, and 2003-2005 Aviator vehicles built before 1/23/2006 may experience a rear power window that sticks in the up position. This condition can be intermittent and may be due to the power motor which temporarily locks up. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Use the current Workshop Manual (WSM), Section 501-11 procedure to remove the door panel and inspect the window regulator for damaged parts. 2. If any damage part or parts are found replace the regulator assembly. 3. If no damaged parts are found on the regulator assembly, replace the window regulator motor using WSM, Section 501-11. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072005A 2002-2005 Explorer Sport 0.9 Hr. Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B 27406B8, 27406B9) 072005B 2002-2005 Explorer Sport 1.6 Hrs. Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > 07-20-5 > Oct > 07 > Body - Rear Door Window Stuck In Up Position/Inoperative > Page 10462 To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9) 072005C 2002-2006 0.4 Hr. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B, 27406B8, 27406B9) 072005D 2002-2006 0.7 Hr. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9) 072005E 2002-2006 0.6 Hr. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B, 27406B8, 27406B9) 07200SF 2002-2006 1.1 Hrs. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9) DEALER CODING CONDITION BASIC PART NO. CODE 7823394 07 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > Page 10463 Rear Door Window Regulator: By Symptom Technical Service Bulletin # 07-20-5 Date: 071015 Body - Rear Door Window Stuck In Up Position/Inoperative TSB 07-20-5 10/15/07 REAR POWER WINDOW MOTOR INOPERATIVE/STUCK IN THE UP POSITION FORD: 2002-2005 Explorer Sport Trac 2002-2006 Explorer LINCOLN: 2003-2005 Aviator MERCURY: 2002-2006 Mountaineer This article supersedes TSB 07-16-14 to update the Part List. ISSUE Some 2002-2006 Explorer, Mountaineer and 2002-2005 Explorer Sport Trac, and 2003-2005 Aviator vehicles built before 1/23/2006 may experience a rear power window that sticks in the up position. This condition can be intermittent and may be due to the power motor which temporarily locks up. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Use the current Workshop Manual (WSM), Section 501-11 procedure to remove the door panel and inspect the window regulator for damaged parts. 2. If any damage part or parts are found replace the regulator assembly. 3. If no damaged parts are found on the regulator assembly, replace the window regulator motor using WSM, Section 501-11. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072005A 2002-2005 Explorer Sport 0.9 Hr. Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B 27406B8, 27406B9) 072005B 2002-2005 Explorer Sport 1.6 Hrs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > Page 10464 Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9) 072005C 2002-2006 0.4 Hr. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B, 27406B8, 27406B9) 072005D 2002-2006 0.7 Hr. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9) 072005E 2002-2006 0.6 Hr. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B, 27406B8, 27406B9) 07200SF 2002-2006 1.1 Hrs. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9) DEALER CODING CONDITION BASIC PART NO. CODE 7823394 07 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > Page 10465 Disclaimer Technical Service Bulletin # 07-20-5 Date: 071015 Body - Rear Door Window Stuck In Up Position/Inoperative TSB 07-20-5 10/15/07 REAR POWER WINDOW MOTOR INOPERATIVE/STUCK IN THE UP POSITION FORD: 2002-2005 Explorer Sport Trac 2002-2006 Explorer LINCOLN: 2003-2005 Aviator MERCURY: 2002-2006 Mountaineer This article supersedes TSB 07-16-14 to update the Part List. ISSUE Some 2002-2006 Explorer, Mountaineer and 2002-2005 Explorer Sport Trac, and 2003-2005 Aviator vehicles built before 1/23/2006 may experience a rear power window that sticks in the up position. This condition can be intermittent and may be due to the power motor which temporarily locks up. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Use the current Workshop Manual (WSM), Section 501-11 procedure to remove the door panel and inspect the window regulator for damaged parts. 2. If any damage part or parts are found replace the regulator assembly. 3. If no damaged parts are found on the regulator assembly, replace the window regulator motor using WSM, Section 501-11. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072005A 2002-2005 Explorer Sport 0.9 Hr. Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B 27406B8, 27406B9) 072005B 2002-2005 Explorer Sport 1.6 Hrs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > Page 10466 Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9) 072005C 2002-2006 0.4 Hr. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B, 27406B8, 27406B9) 072005D 2002-2006 0.7 Hr. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9) 072005E 2002-2006 0.6 Hr. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B, 27406B8, 27406B9) 07200SF 2002-2006 1.1 Hrs. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9) DEALER CODING CONDITION BASIC PART NO. CODE 7823394 07 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > Page 10467 Disclaimer Technical Service Bulletin # 07-20-5 Date: 071015 Body - Rear Door Window Stuck In Up Position/Inoperative TSB 07-20-5 10/15/07 REAR POWER WINDOW MOTOR INOPERATIVE/STUCK IN THE UP POSITION FORD: 2002-2005 Explorer Sport Trac 2002-2006 Explorer LINCOLN: 2003-2005 Aviator MERCURY: 2002-2006 Mountaineer This article supersedes TSB 07-16-14 to update the Part List. ISSUE Some 2002-2006 Explorer, Mountaineer and 2002-2005 Explorer Sport Trac, and 2003-2005 Aviator vehicles built before 1/23/2006 may experience a rear power window that sticks in the up position. This condition can be intermittent and may be due to the power motor which temporarily locks up. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Use the current Workshop Manual (WSM), Section 501-11 procedure to remove the door panel and inspect the window regulator for damaged parts. 2. If any damage part or parts are found replace the regulator assembly. 3. If no damaged parts are found on the regulator assembly, replace the window regulator motor using WSM, Section 501-11. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 072005A 2002-2005 Explorer Sport 0.9 Hr. Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B 27406B8, 27406B9) 072005B 2002-2005 Explorer Sport 1.6 Hrs. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > Page 10468 Trac: Replace The Rear Door Window Motor Or Regulator, Includes Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9) 072005C 2002-2006 0.4 Hr. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B, 27406B8, 27406B9) 072005D 2002-2006 0.7 Hr. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Motor, Includes Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9) 072005E 2002-2006 0.6 Hr. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes Time To Remove And Install Interior Door Trim Panel: One Rear Door (Do Not Use With 27406B, 27406B8, 27406B9) 07200SF 2002-2006 1.1 Hrs. Explorer/Mountaineer, 2003-2005 Aviator: Replace The Rear Door Window Regulator, Includes Time To Remove And Install Interior Door Trim Panel: Both Rear Doors (Do Not Use With 27406B, 27406B8, 27406B9) DEALER CODING CONDITION BASIC PART NO. CODE 7823394 07 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Window Regulator: > Page 10469 Disclaimer Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Technical Service Bulletins > Page 10470 Rear Door Window Regulator: Service and Repair Heavy Duty Riverter SPECIAL TOOL(S) REMOVAL 1. Raise and support the rear door window glass to the full up position. 2. Remove the interior door handle. 3. Remove the rear door speaker. 1 Remove the screws. 2 Disconnect the electrical connector. 3 Remove the speaker. 4. Remove the water shield. 5. Disconnect the rear door window regulator motor electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Technical Service Bulletins > Page 10471 6. Remove the rear door window regulator rivets. 7. Remove the rear door window regulator. ^ Slide the regulator arms off of the window glass track. INSTALLATION 1. To install, reverse the removal procedure. ^ Use the special tool to install the rivets. ^ Cycle the door glass to make sure of engagement of the drive mechanism. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Technical Service Bulletins > Page 10472 Heavy Duty Riveter Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Technician Safety Information Windshield: Technician Safety Information WARNING: TO PREVENT GLASS SPLINTERS FROM ENTERING THE EYES OR CUTTING HANDS, WEAR SAFETY GLASSES AND HEAVY GLOVES WHEN CUTTING THE GLASS FROM THE VEHICLE. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Technician Safety Information > Page 10477 Windshield: Vehicle Damage Warnings CAUTION: ^ After installing the urethane installed glass, the vehicle should not be driven until the urethane adhesive has cured. The curing times at temperatures above 13°C (55°F) and relative humidity above 50% is 12-24 hours (refer to Essex Drive Away Chart for cure times, as temperatures and humidity vary). Inadequate curing of the urethane adhesive may adversely affect the strength of the urethane bond. ^ Do not scratch the pinch weld area. ^ If the vehicle is to be driven within 24 hours of urethane application, urethane adhesive Essex U-216 must be used due to its one hour cure time. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 10478 Windshield: Service and Repair SPECIAL TOOL(S) REMOVAL WARNING: TO PREVENT GLASS SPLINTERS FROM ENTERING THE EYES OR CUTTING HANDS, WEAR SAFETY GLASSES AND HEAVY GLOVES WHEN CUTTING THE GLASS FROM THE VEHICLE. 1. Remove the windshield side garnish mouldings. 2. Remove the interior rear view mirror. 3. Remove the overhead console. 4. Remove the sun visors. 1 Remove the sun visor screws. 2 Remove the sun visors. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 10479 ^ If equipped, disconnect the electrical connector. 5. Remove the sun visor clips. 1 Remove the sun visor clip screws. 2 Remove the sun visor clips. 6. Lower the front portion of the headliner. 7. Remove the cowl grille. 8. Remove the upper windshield weatherstrip. 9. Remove the LH and RH windshield mouldings. 10. Using a soft brush or vacuum, remove any dirt or foreign material from the pinch weld. 11. Using the special tool, cut the urethane adhesive from the windshield glass starting at the top center and work toward the bottom corners. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 10480 NOTE: Lubricate the urethane adhesive with water to aid the special tool when cutting. 12. Using the special tool, distance the windshield from the body. 13. Using the special tool, cut the remaining urethane adhesive and remove the windshield glass. 14. Using a soft brush or vacuum, remove any foreign material or dirt from the pinch weld. INSTALLATION CAUTION: After installing the urethane installed glass, the vehicle should not be driven until the urethane adhesive has cured. The curing times at temperatures above 13°C (55°F) and relative humidity above 50% is 12-24 hours (refer to Essex Drive Away Chart for cure times, as temperatures and humidity vary). Inadequate curing of the urethane adhesive may adversely affect the strength of the urethane bond. 1. Dry fit the windshield. Make alignment marks with tape or non-staining grease pencil. 2. Trim the remaining urethane adhesive on the pinch weld to within the specification. ^ The existing urethane adhesive surface should be smooth and free of cuts and contamination. CAUTION: Do not scratch the pinch weld area. 3. Use a wool applicator to apply Urethane Metal Primer Essex U-413 meeting Ford specification WSB-M2G234-C to any exposed metal on the pinch weld. Allow six to ten minutes to dry. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 10481 4. Apply (A) Foam Dam meeting Ford specification WSB-M2G234-C to the (B) pinch weld. 5. If reinstalling original windshield, remove the excess urethane adhesive from the windshield glass. 6. Clean the inside of the glass surface with an alcohol-free cleaner making sure the ceramic coated area is clean. 7. If installing a new windshield glass, apply Urethane Glass Prep Essex U-401 meeting Ford specification WSB-M2G314-B twice around the glass surface to be urethaned. NOTE: Wipe off the Glass Prep immediately after each application because it flash dries. 8. If installing a new windshield glass, apply Glass Primer Essex U-402 meeting Ford specification WSB-M5B280-C to the same area that was prepped in the pervious step. Allow five minutes to dry. 9. Cut the urethane adhesive applicator tip to specification. 10. Apply a bead of urethane adhesive Essex 400-HV or Essex U-216, which meets Ford specification WSB-M2G316-B to the pinch weld just outside the foam dam. CAUTION: If the vehicle is to be driven within 24 hours of urethane application, urethane adhesive Essex U-216 must be used due to its one hour cure time. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 10482 11. Install the windshield glass aligning it to the marks previously made. 12. After the windshield glass is set, check for water leaks and add urethane adhesive where needed. 13. Install the upper windshield weatherstrip. 14. If necessary, remove excess urethane adhesive from the outside surface of the windshield glass. 15. Install the LH and RH windshield mouldings. 16. Install the Cowl grille. 17. Install the overhead console. 18. Install the sun visor clips. 1 Position the sun visor clips. 2 Install the screws. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 10483 19. Install the sun visors. 1 Position the sun visors. ^ If equipped, connect the electrical connector. 2 Install the screws. 20. Install the front portion of the headliner. 21. Install the interior rear view mirror. 22. Install the windshield side garnish mouldings. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 10484 Special Tool(s) Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Application and ID Windshield Washer Control Module: Application and ID For further information please see Accessories and Optional Equipment, General Module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations Windshield Washer Relay: Locations Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 10493 Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 10494 Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Windshield Washer Relay Connector View C1004 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Windshield Washer Relay > Page 10497 Connector View C1039 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Page 10498 Windshield Washer Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Page 10499 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Application and ID Wiper Control Module: Application and ID For further information please see Accessories and Optional Equipment, General Module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay Wiper Relay: Locations Wiper High/Low Relay Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 10507 Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 10508 Wiper Relay: Locations Wiper Run/Park Relay Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 10509 Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Wiper High/Low Relay Connector View C1001 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Wiper High/Low Relay > Page 10512 Connector View C1002 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Wiper High/Low Relay > Page 10513 Connector View C1036 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Wiper High/Low Relay > Page 10514 Connector View C1037 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Wiper High/Low Relay > Page 10515 Connector View C1059 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Page 10516 Wiper Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Page 10517 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams Windshield Washer Switch: Diagrams Connector View C202a Connector View C202b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 10522 Windshield Washer Switch: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 10523 Multifunction Switch, Wiper/Washer Portion Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 10524 Multifunction Switch, Wiper/Washer Portion Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Multifunction Switch Wiper Switch: Diagrams Multifunction Switch Connector View C202a Connector View C202b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Multifunction Switch > Page 10529 Connector View C467 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Multifunction Switch > Page 10530 Connector View C2000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 10531 Wiper Switch: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 10532 Multifunction Switch, Wiper/Washer Portion Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 10533 Multifunction Switch, Wiper/Washer Portion Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 10534 Wiper Switch: Service and Repair REMOVAL 1. Remove the instrument panel finish panel. 1 Remove the screws. 2 Remove the center instrument panel finish panel. ^ Disconnect the electrical connectors. 2. Remove the rear wiper/washer switch. 1 Remove the screws. 2 Remove the mounting bezel. 3 Release the two tabs and remove the rear wiper/washer switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Application and ID Windshield Washer Control Module: Application and ID For further information please see Accessories and Optional Equipment, General Module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams Connector View C137 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service Precautions Windshield Washer Pump: Service Precautions WARNING: WINDSHIELD WASHER SOLUTION CONTAINS METHANOL, WHICH IS POISONOUS. OBSERVE ALL CAUTIONS AND WARNINGS INDICATED ON THE LABEL OF THE WASHER SOLUTION CONTAINER. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service Precautions > Page 10544 Windshield Washer Pump: Service and Repair REMOVAL 1. Remove the engine air cleaner. 2. Remove the windshield wiper reservoir fasteners. 1 Remove the two screws. 2 Remove the two nuts 3. Disconnect the windshield washer reservoir pump electrical connector. 4. Disconnect the windshield washer hose from the windshield washer pump and plug the outlet of the pump. WARNING: WINDSHIELD WASHER SOLUTION CONTAINS METHANOL, WHICH IS POISONOUS. OBSERVE ALL CAUTIONS AND WARNINGS INDICATED ON THE LABEL OF THE WASHER SOLUTION CONTAINER. 5. Disconnect the coolant overflow hose from the engine coolant overflow reservoir and plug the outlet of the reservoir Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service Precautions > Page 10545 6. Remove the windshield washer pump. NOTE: Make sure not to damage the rubber grommet during disassembly. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations Windshield Washer Relay: Locations Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 10549 Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 10550 Auxiliary Relay Box 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Windshield Washer Relay Connector View C1004 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Windshield Washer Relay > Page 10553 Connector View C1039 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Page 10554 Windshield Washer Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Page 10555 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service Precautions Windshield Washer Reservoir: Service Precautions WARNING: WINDSHIELD WASHER SOLUTION CONTAINS METHANOL, WHICH IS POISONOUS. OBSERVE ALL CAUTIONS AND WARNINGS INDICATED ON THE LABEL OF THE WASHER SOLUTION CONTAINER. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service Precautions > Page 10559 Windshield Washer Reservoir: Service and Repair REMOVAL 1. Remove the engine air cleaner. 2. Remove the windshield wiper reservoir fasteners. 1 Remove the two screws. 2 Remove the two nuts 3. Disconnect the windshield washer reservoir pump electrical connector. 4. Disconnect the windshield washer hose from the windshield washer pump and plug the outlet of the pump. WARNING: WINDSHIELD WASHER SOLUTION CONTAINS METHANOL, WHICH IS POISONOUS. OBSERVE ALL CAUTIONS AND WARNINGS INDICATED ON THE LABEL OF THE WASHER SOLUTION CONTAINER. 5. Disconnect the coolant overflow hose from the engine coolant overflow reservoir and plug the outlet of the reservoir Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service Precautions > Page 10560 6. Remove the windshield washer pump. NOTE: Make sure not to damage the rubber grommet during disassembly. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams Windshield Washer Switch: Diagrams Connector View C202a Connector View C202b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 10564 Windshield Washer Switch: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 10565 Multifunction Switch, Wiper/Washer Portion Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 10566 Multifunction Switch, Wiper/Washer Portion Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Adjustments Wiper Arm: Adjustments 1. Cycle and park the windshield wipers. 2. Verify the distance between the center of the passenger windshield wiper blade and the rear edge of the cowl top vent panel is within specifications. 3. Verify the distance between the center of the driver windshield wiper blade and the rear edge of the cowl top vent panel is within specifications. 4. If the distance is not within specifications, remove the windshield wiper pivot arms and reposition to specification. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Rear Pivot Arm Wiper Arm: Service and Repair Rear Pivot Arm REMOVAL 1. Disconnect the rear washer hose. NOTE: Early build shown, late build similar. 2. Remove rear wiper pivot arm. 1 Lift the wiper pivot arm nut cover at the point shown. 2 Remove the nut. 3 Remove the wiper pivot arm. NOTE: The wiper pivot arm must be lifted straight up from the shaft to avoid damage to the wiper pivot arm or shaft. NOTE: Early build shown, late build similar. INSTALLATION 1. Turn the rear wiper switch on and allow the motor to operate for at least one cycle. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Rear Pivot Arm > Page 10572 2. Turn the rear wiper switch OFF. NOTE: This step makes sure that the wiper motor is in the park position. 3. On early build vehicles, position the rear wiper blade outside the wiper arm stop. 4. Install the wiper pivot arm onto the wiper motor. ^ Tighten retaining nut. NOTE: Early build shown, late build similar. 5. Connect the washer hose to the elbow with elbow positioned between the 9:00 and 12:00 o'clock positions. NOTE: Early build shown, late build similar. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Rear Pivot Arm > Page 10573 Wiper Arm: Service and Repair Front Wiper Pivot Arm REMOVAL 1. Remove the wiper pivot arm. 1 Pull up on the wiper pivot arm. 2 Pull out on the retainer tab and lower the wiper pivot arm to the tab. 3 Remove the wiper pivot arm. NOTE: The wiper pivot arms are installed as an assembly. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Adjustments Wiper Blade: Adjustments 1. Cycle and park the windshield wipers. 2. Verify the distance between the center of the passenger windshield wiper blade and the rear edge of the cowl top vent panel is within specifications. 3. Verify the distance between the center of the driver windshield wiper blade and the rear edge of the cowl top vent panel is within specifications. 4. If the distance is not within specifications, remove the windshield wiper pivot arms and reposition to specification. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Application and ID Wiper Control Module: Application and ID For further information please see Accessories and Optional Equipment, General Module. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Windshield Wiper Motor Connector View C125 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Windshield Wiper Motor > Page 10584 Wiper Motor: Diagrams Rear Wiper Motor Assembly Connector View C476 Connector View C4171 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Page 10585 Wiper Motor: Service Precautions CAUTION: ^ The internal permanent magnets used in the windshield wiper motor are made of a glass-like material. To avoid damaging the magnets, do not strike the motor with a hammer or any other object. ^ Read the installation label on the rear wiper motor before installing in vehicle to prevent component damage. Do not activate rear wiper motor until windshield wiper arm and blade are correctly installed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Page 10586 Wiper Motor: Testing and Inspection Use Alternator, Regulator, Battery and Starter Tester (ARBST) to test the wiper motor on the vehicle. To test the wiper motor, disconnect the windshield wiper mounting arm and pivot shaft from the windshield wiper motor. Disconnect the wiper motor. Connect the (1) green lead from (2) Alternator, Regulator, Battery and Starter Tester (ARBST) to the battery negative (-) post. Connect the (3) red lead from ARBST to the wiper motor (4) common brush terminal (terminal 3). Test the low speed mode by connecting a (5) cable from the battery positive (+) post to the (6) low speed brush terminal (terminal 4) and measure the current draw. If the current draw is greater than 3.5 amperes, install a new windshield wiper motor. Test the high speed mode by connecting a cable from the battery positive (+) post to the (7) high speed brush terminal (terminal 5) and measure the current draw. If the current draw is greater than 5.5 amperes, install a new wiper motor. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Windshield Wiper Motor Wiper Motor: Service and Repair Windshield Wiper Motor REMOVAL 1. Disconnect the washer hose from the LH washer jet nozzle. 2. Remove the cowl grilles. 3. Unsnap the wiper motor clip from the RH wiper mounting arm and pivot shaft. 4. Disconnect the RH wiper mounting arm and pivot shaft from the LH wiper mounting arm and pivot shaft and move both away from the windshield wiper motor. 5. Disconnect the electrical connector. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Windshield Wiper Motor > Page 10589 6. Remove the ground strap nut and position the strap aside. 7. Remove the windshield wiper motor. ^ Remove the stud bolts. ^ Remove the bolts. CAUTION: The internal permanent magnets used in the windshield wiper motor are made of a glass-like material. To avoid damaging the magnets, do not strike the motor with a hammer or any other object. INSTALLATION 1. Install the windshield wiper motor. 1 Install the windshield wiper motor. 2 Install the stud bolts. 3 Install the bolts. CAUTION: The internal permanent magnets used in the windshield wiper motor are made of a glass-like material. To avoid damaging the magnets, do not strike the motor with a hammer or any other object. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Windshield Wiper Motor > Page 10590 2. Install the ground strap and nut. 3. Connect the electrical connector. 4. Install the wiper mounting arm and pivot shaft arms to the windshield wiper motor. 1 Install the LH wiper mounting arm and pivot shaft onto the windshield wiper motor crank pin. 2 Install the RH wiper mounting arm and pivot shaft onto the wiper motor crank pin. 3 Push the retaining clip until it snaps into place. 5. Install the cowl grilles. 6. Connect the washer hose to the LH washer jet nozzle. 7. Install the LH wiper pivot arm. 8. Adjust the LH wiper pivot arm. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Windshield Wiper Motor > Page 10591 Wiper Motor: Service and Repair Rear Window Wiper Motor REMOVAL 1. Remove the rear wiper pivot arm. 2. Remove the liftgate door trim panel. 3. Remove the watershield. 4. Remove rear wiper motor. 1 Disconnect electrical connector. 2 Remove three retaining bolts. 3 Remove rear wiper motor. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Read the installation label on the rear wiper motor before installing in vehicle to prevent component damage. Do not activate rear wiper motor until windshield wiper arm and blade are correctly installed. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Service Precautions Wiper Motor Linkage: Service Precautions CAUTION: To avoid possible damage to the windshield wiper adapter and connecting arm clip, be sure the clip is fully seated before installing the adapter and connecting arm clip on the windshield wiper motor crank pin. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Service Precautions > Page 10595 Wiper Motor Linkage: Service and Repair REMOVAL 1. Remove the cowl grilles. 2. Unsnap the wiper motor clip from the RH wiper mounting arm and pivot shaft. 3. Disconnect the RH wiper mounting arm and pivot shaft from the LH wiper mounting arm and pivot shaft and move both away from the windshield wiper motor. 4. Remove the RH and LH wiper mounting arm and pivot shafts. 1 Remove the two nuts. 2 Remove the wiper mounting arm and pivot shafts. INSTALLATION 1. Install the RH and LH wiper mounting arms and pivot shafts. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Service Precautions > Page 10596 1 Position the wiper mounting arm and pivot shafts into place. 2 Install the two nuts. 2. If removed, install the clip onto the RH wiper mounting arm and pivot shaft. CAUTION: To avoid possible damage to the windshield wiper adapter and connecting arm clip, be sure the clip is fully seated before installing the adapter and connecting arm clip on the windshield wiper motor crank pin. 3. Install the wiper mounting arm and pivot shaft assemblies. 1 Install the LH wiper mounting arm and pivot shaft onto the windshield wiper motor crank pin. 2 Install the RH wiper mounting arm and pivot shaft onto the wiper motor crank pin. 3 Push the retaining clip until it snaps into place. 4. Install the cowl grilles. 5. Adjust the LH and RH wiper pivot arms. Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay Wiper Relay: Locations Wiper High/Low Relay Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 10601 Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 10602 Wiper Relay: Locations Wiper Run/Park Relay Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 10603 Part 1 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Wiper High/Low Relay Connector View C1001 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Wiper High/Low Relay > Page 10606 Connector View C1002 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Wiper High/Low Relay > Page 10607 Connector View C1036 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Wiper High/Low Relay > Page 10608 Connector View C1037 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Wiper High/Low Relay > Page 10609 Connector View C1059 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Page 10610 Wiper Relay: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Page 10611 Relay - Mini ISO Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Multifunction Switch Wiper Switch: Diagrams Multifunction Switch Connector View C202a Connector View C202b Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Multifunction Switch > Page 10616 Connector View C467 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Multifunction Switch > Page 10617 Connector View C2000 Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 10618 Wiper Switch: Testing and Inspection Introduction To Component Testing Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 10619 Multifunction Switch, Wiper/Washer Portion Ford Explorer Sport Trac 2wd Workshop Manual (V6-4.0L VIN E (2002)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 10620 Multifunction Switch, Wiper/Washer Portion